Justin Arbesman
Project 2B: Topology Optimization
Project 2B: Topology Optimization
Detail Intent
The natural world exists in resource scarcity. All forms of life have hidden optimizations within that allow for their form to exist. Bird skulls have three layers each connected with what can be called columns of microscopic bone allowing for a light yet rigid structure to not weigh the bird down. Lily Pads stem from a single root and branch out varying the thickness of their components depending on the forces acting on it. These natural optimization processes in nature beautifully tackle the organisms largest hurdles when it comes to living on this planet. We now have begun to deconstruct and reinvent these processes in the digital age. Utilizing these algorithmic processes, we can take our first principles of design and elevate them to a human designed nature. While not entirely necessary on this project by Herzog and de Meuron, the method of topology optimization is a field beginning to take over the aerospace and automotive industries and thus should be looked at in the world of architecture.
The natural world exists in resource scarcity. All forms of life have hidden optimizations within that allow for their form to exist. Bird skulls have three layers each connected with what can be called columns of microscopic bone allowing for a light yet rigid structure to not weigh the bird down. Lily Pads stem from a single root and branch out varying the thickness of their components depending on the forces acting on it. These natural optimization processes in nature beautifully tackle the organisms largest hurdles when it comes to living on this planet. We now have begun to deconstruct and reinvent these processes in the digital age. Utilizing these algorithmic processes, we can take our first principles of design and elevate them to a human designed nature. While not entirely necessary on this project by Herzog and de Meuron, the method of topology optimization is a field beginning to take over the aerospace and automotive industries and thus should be looked at in the world of architecture.
Structural engineers and architects are able to integrate the structural optimization in parallel with the standard structural calculations. Using software that is fed material properties, movement constraints, loads and load direction, the architect and engineer are able to generate force optimized forms. These forms are then further refined after the initial simulation and fed into a CAD/CAM program. With the use of a 5-axis CNC robot arm, the prefabricated components would be stripped of unnecessary material directly after the part is dimensioned. The component would then be equipped with standard heavy timber connections and used without disruption to the labor force. However, the 5-axis CNC is also capable of implementing custom complex joinery onto the part during the shaving process.
Tectonics
Then looking at a part designed using topology algorithms, even the laymen gets a feeling like nature had a role to play. The intricate, organic, and often beautiful forms that emerge give a sense of otherworldliness or of a stream of design almost unimaginable. Only through recreating processes of nature do these forms exist. Perfectly suited to its structural purposes, the optimized components visually convey the laws of nature. The results intertwine human created and naturally grown forms, a visual look into the fabric of the world. Tendrils span from one side to another, changing in size and shape showcasing the forces it counteracts. Maybe by looking at these forms more closely will we be able to further understand and conceive of structures for tomorrow.
Materiality
While topology optimization works on virtually any material, wood may be one of the best for the process. Wood has been carved, joined, spanned, bent, and cut for centuries. It is a material perfect for machining with little resistance to tools yet great overall volumetric strength. With manufacturing methods of today, any size lumber can be created by methods such as glulam allowing for large components ready for CNC milling at a staggeringly low cost in relation to its size vs raw lumber. Many professional fabrication companies are becoming custom to 5-Axis CNC milling so the topology optimization workflow can be used in unison without extra training or equipment investment.
Results
components that emerge from topology optimization have a weight reduction of around 20 - 50% depending on the material and geometry of the part. Leaving only what is necessary, offcuts can then be reused in different manufacturing processes. And due to the method of 5-axis CNC, the cost per part is only time based, the complexity has no bearing on final price outcome. These combine to have structures that can be smaller, lighter, cost roughly the same to manufacture as standard prefabricated parts, and supply derivative industries with offcuts. Topology optimization can form to any force and any load assuming the material is able to withstand it in the first place. It may be some time before methods like this are implemented but it will surely replace the crude, rigid, and often unsightly man-made structural elements of today.
While topology optimization works on virtually any material, wood may be one of the best for the process. Wood has been carved, joined, spanned, bent, and cut for centuries. It is a material perfect for machining with little resistance to tools yet great overall volumetric strength. With manufacturing methods of today, any size lumber can be created by methods such as glulam allowing for large components ready for CNC milling at a staggeringly low cost in relation to its size vs raw lumber. Many professional fabrication companies are becoming custom to 5-Axis CNC milling so the topology optimization workflow can be used in unison without extra training or equipment investment.
components that emerge from topology optimization have a weight reduction of around 20 - 50% depending on the material and geometry of the part. Leaving only what is necessary, offcuts can then be reused in different manufacturing processes. And due to the method of 5-axis CNC, the cost per part is only time based, the complexity has no bearing on final price outcome. These combine to have structures that can be smaller, lighter, cost roughly the same to manufacture as standard prefabricated parts, and supply derivative industries with offcuts. Topology optimization can form to any force and any load assuming the material is able to withstand it in the first place. It may be some time before methods like this are implemented but it will surely replace the crude, rigid, and often unsightly man-made structural elements of today.
Justin Arbesman
Material Design Innovation P2C
Material Design Innovation P2C
Topology Optimization
Recent innovations in digital fabrication, specifically related to the emerging field of 3D printed concrete formwork, has opened the doors to projects that use extremely complex geometry while having the cost of formwork be fixed to just material usage and time on a viable printing robot. This field of research has discovered the usage of automotive and industrial structural optimization software into the realm of architecture. Previously the geometries generated were only references for engineers to design optimal structural paths to save weight on parts, however in the case of concrete, a material that has the properties of both fluid and solid, the actual mesh generated from these optimization softwares can be used to create forms that have roughly 70% less material than their original unchanged volume.
Recent innovations in digital fabrication, specifically related to the emerging field of 3D printed concrete formwork, has opened the doors to projects that use extremely complex geometry while having the cost of formwork be fixed to just material usage and time on a viable printing robot. This field of research has discovered the usage of automotive and industrial structural optimization software into the realm of architecture. Previously the geometries generated were only references for engineers to design optimal structural paths to save weight on parts, however in the case of concrete, a material that has the properties of both fluid and solid, the actual mesh generated from these optimization softwares can be used to create forms that have roughly 70% less material than their original unchanged volume.
Method
As seen in projects by ETH in Zurich, the output of these softwares are inverted and converted into a mold that is then 3D printed with either plastics for repeat casting or dissolvable molds for extremely intricate components. In this detail, I generated a concrete cantilever using the topology optimization capabilities of Fusion 360 and fed the results into Rhino 7 to better manipulate the geometry. The result is a form that has both the benefit of looking at a very specific organic aesthetic while also using only 30% of the concrete needed for its shape as compared to traditional forming methods.
To emphasize the generated design, the pieces are bolted to a 5-ply CLT spine that runs through the whole stair. Thin wooden veneers are placed as treads to hide the mounting holes and to match the CLT spine while glass is used as the main railing support and is bolted to the edges of the concrete generated wing. The railing is held on using a minimal steel (or aluminum) connector that references the angles generated in the topology optimized concrete part. The juxtaposition of minimalism and organic geometry accentuates both and allows the stair to fit into the current aesthetic of my building while showcasing the potential projects that the digital fabrication facility is capable of creating.