acANDe 23 Proceedings ofthe 28rd Conference on Education in Computer Aided Architectural Design in Europe 21-24.09.2005 Institute Superior Técnico, Technical University of Lisbon Portugal \ww.chvistutLpt/ecaade05 Edited by José Pinto Duarte Gongalo Ducta-Soares ‘A.2ta SampaioSession 5: Fabrication Digital Desires, Material Realities 221 Perceiving the technological gay ‘José Pecro Sous, José Pinto Duarte Computer-Aided Architectural Design vs. Architect-Aided Computing Design 229 Architecticomputer interaction in the digital design process on the example of ‘advanced CAAD/CAAM project ‘Agnieszka Sowa The “BASYS”-house - From a Research Project to Practice - ahouse ina day 237 Ciaus-Jargen Schink, Holger Kénig, Manfred Krines Design for Manufacturing In Architecture 245 Mapping In between Curved Surtaces Design and Fabrication Edvard Lyon ‘Towards Ornamatics 253 Jack Breen, Martin Stelingwertt Design Production: Constructing Freeform Designs with Rapid Prototyping 261 Lawrence Sass, Kristina Shea , Michael Powell Ceramic Covers 269 Rethinking Roof Tiles in a Contemporary Context Luisa Caldas, José Ouarte ‘session 5: fabrication - @CAAD@ 23 | 219Digital Desires, Material Realities Perceiving the technological gap José Pedro Sousa, José Pinto Duarte ISE-UTL, Instituto Superior Técnico, Technical University of Lisbon, Portugal Ip: /ivsveiseutl pt Abstract, Digital design and manufacturing technologies are progressively em- ployed in building construction and architects interest in this field has grown widely, as many recent works, publications and scientific meetings demonstrate. By identifying some of the main reasons and expectations that were at the basis of the integration of CAD/CAM processes in the discipline, this paper examines the real success of these technological developments in contemporary architecture. By analyzing current work and literature the authors argue that there is often a discrepancy between the discourse on emerging new conditions for the practice, ‘and the practical reality itself. To investigate this technological gap, the paper discusses in depth one of the most advocated promises of these new technologies: the feasible mass production of differentiation. Considering design intent, available CNC fabrication processes and material properties, it describes and critically analyses different strategies for ‘building architectural surfaces, presenting specific examples from contemporary archivecture. Realizing that there are technological limitations in the fulfilment of conceptual aspirations, this paper identifies possible innovative directions in ‘building construction, based on the idea of structural performative surfaces. Finally, the authors reflect on the specific nature of architecture, distinguishing it from other areas that also employ digital technologies, to frame, from within the discipline, the technological expectations and its potential further developments. Keywords, CAD/CAM, Digital Fabrication, CNC Technologies, Rationalization, ‘Mass-Customization. 4. Introduction 141 The Integration of CADCAM in Architec- ture (Over the last 80 years, the dissemination of the computer has affected the practice of architec ture in many ways: from drawing automation and virtual representation, to the contemporary digital techniques that assist design conception. For ar- chitects, the increasing fascination with compu- tational tools generated a renowod Intorest in the ‘exploration of complex geometries by means, for Instance, of animation, parametric, generative or ‘evolutionary techniques. However, this tendency ‘00n revealed the limitations of existing construc- session 5: fabrication - @CAADe 23 | 221tion technology, ruled by standardization, pre-fab- rication and mass-production principles. Despite Using flexible tools for the generation and control of intricate shapes, architecs stl faced extreme lficuites to translate them into the physical realm. ‘This situation crew a clear gap between digitally conceived Ideas and their material constructed reallties, which often fed conservative discourses against the introduction of new technologies in ar- ctitecture, both in practice and academia, In this context, architects tuned to other de- ‘sign-telated fields in search for technological help. Possible answers came from automotive, aero- ‘space, shipbuilding or product design industries, ‘where computer-sided desion and manufacturing technologies (CAD-CAM) were employed to pro- ‘duce geometrically diverse and complex compo- nents. This exchange revealed that a wice range of ‘computer numerically controled (CNC) fabrication processes were available to work with diferent materials, using deta trom digital design models. ‘Thus, this ciitl continuity from design to fabrica tion promised to bridge the previous gap, wile suggesting new opportunities for architectural practice, 4.2 Digital Desires, Material Realtios ‘Today, CAD/CAM technologies are increas- Ingly omployed in the bullding industry and ex- plored in most leading academic environments, ‘The disciplinary interest in this fleld has grown ‘widely over the past few years. Since 2001, several ‘authors have written and edited concise publice- tions on the theme (Le. Callicott, 2001; Bechthold ft al, 2001 and 2003; Kolarevi, et al, 2003 and 2005; Leach, etal, 2004; Schodeck, et al, 2005), and digital fabrication has become a major theme In architectural sciontiic meetings (2. the past AAIAIACADIA conferonce that was fully dedicated to Fabrication). Together, all these references have Provided Insight into the taxonomy of CADICAM technologies and its techniques, reviewed the history of ts implementation in the dsciptine, pre- 222 | sCAADe 29. session 6: fabrication sented and llustrated innovative case-studles, and outlined the emergence of new dasign and bulld- ing construction paradigms. Moreover, these tech- nologies have stimulated the optimistic view “that design vocabularies can be expanded and that these same designs can be made with a quality and precision previously ciclo achieve" (Shodeck, ‘etal, 2005), while their impact on architecture has “Tiangulation, flattening or unfolding are becom- Ing common routines to link design to CNC cutting processes, which tend to lead architects towards fationalization processes, like the ones represent- din 1.A and 1.8. Among all existent categories Of digital fabrication technologies, as defined by Volker (1997: 69), the paricular case of cutting, within subtractive fabricstion, seems tobe the only ‘one tat, infact, can really achiove feasible mass production of difereniated shapes. By involving simple machining planning procedures, a single ‘operation of contouring, and the use of thin ma- terials, two-dimensional CNC cutting processes fare fast and permit the production of ciferentated shapes as easy as if they were all identical. Kas (osterhuls' Web of North Holland project isan ex- ample of the use of digital technology to design ‘and build an entire architectural construction to- tally made out of lat components. The ofice used Jaser-cutting processes to manufacture both the structural and the cladding system. Given that ac- ‘commadating repotiive parts is usually easier to plan, the critical aspect of diferentated fabrication li in optimizing the raw sheet material forthe pro- duction of multiple components, and in assuring an efficient system of incivicual identification to a= low and orient thet future assomibage. in Ooster- huis’ project, customized scripted procedures were developed to analyze the geometry and flat ten the resulting components for later CNC cutting ‘Thus, significant ime and economic advantages in design and fabrication explain the common prefer- tence for these two strategies. FIGURE 2: The sree at hatment and orsaton of the varia fact cancer Ing prncton process, ae ‘oil propery an ln Ion quale #0 dee ‘onion for scfm ‘plenetarons of CADICAM frarchecnFIGURE 3: Fabrication proce tier tet co be ed ee trate 2D carved components with hich by mew of omputer american) tecnignes. homes proc tous tries can be de Fira Aor (3) sig rmolds ond formvork whe ‘ehere ot be rehped.by rnechnl ervnton (9. Sibwacine “proses can den a dexoed 3D pr fom ‘ro Bok of mater, = i (On the other hand, the exploration of building ‘curved surfaces out of three dimensional materials (1.0) imposes totaly diferent constraints. The dia- ‘grams on FIGURE S represent different processes te produce solid curves components using digital formative and subtractive technologies. In contrast with CNC cutting, all of them imply intricate fab- rication planning procedures, longer periods of ‘manufacturing and sustainable concerns regard- Ing the wasted meteral that is left in subtractive fabrication. Given that the scale of architecture Implies a conetruction with soveral components, it Is easy to realize how this complexity gots muli- pled by a large factor. For instance, when working With structural materials ike wood, stone or metal, subtractive processes are hard time-consuming because the tools cannot run fast on rigid thick surfaces, which requires long machining periods to remove the essential layers of material. Futher- ‘more in order to obtain the desired geometry in al the faces of a given part, one has to plan the posi- tion and fixation systems to orient and support the raw material in the machine. Facing this complox- ly, architects tend to avoid applying these systems to design large scale structures. Thus, employing GNC milled stones, the extension of the Sagrada Familia fn Barcelona is one of the fow examples that can be found of the application of subtrac- tive technologies application to directly produce builsing components. Indeed, most ofthe applica- tions involving 3D components in architecture are explorations of formative processes dered from ‘ormwork and molds previously produced by sub- 3A 3B aT @ 3c 3D tractive processes. n this fashion, architects se- lect economic and light materials that can be high speed machined through subtractive fabrication. Givon that a significant amount of material is usu- ally wasted, its recyclable quality Is also a crucial factor for keeping the whole manufacturing pro- 28s both economically and ecologically feasible. Considering that formworks and molds only need tobe machined trom one sie, the planning and as- sistance procedures for fabrication are significant- ly simplified. At the end ofthe process, formworks fare used to cast liquid materials while molds are tusod to reshape solid ones under heating, steam ft pressure conditions. Using these techniques, Frank Gehry explored recyclable Styrofoam blocks to cast concrote elemontsin the Zollhof Complexin DDussoldort, and CNC milled molds for subsequent thermal deformation of glazed panels in the Conde [Nasté Cafeteria in New York. A similar strategy was uusod by Bernard Franken In the BMW “Bubble” Pavilion in Frankfurt and by Peter Cook and Colin Fourier in the Kunsthaus in Graz. 2.4 Directions and Opportunities The various strategies for bullding architec tural surfaces described in subchapter 2.2 carry the old problematic relationship betwoen skin and structure, Following the classification proposed by Yun (2001: 8), It is possible to conclude that most ‘common applications of CADICAM In archltec- {ure -the ones that also involve higher dimensions of rationalization are curiously connected to the session 5: fabrication @CAADe 23 | 228‘modernist paradigm of separation between skin and structure. Stil following this concept, an ad- vanced development consists in the exploration of CAD/CAM technologies to move beyond the use of Independent straight structures to support curved ‘envelope surfaces, to design and fabricate struc- ‘ures that actually share and follow the curvature Of the skins. The exploration of the geometric in- torolation between structure and skin seems to bbe a possible path towards innovation in building construction. ‘An alternative to this approach relies in the exploration of “stiff shaped surface that serves both as primary load-bearing structure and enclo- sure” (Yun, 200: 8), which falls into the 1.C strat- ay. Therefore, its precisely in this less explored constructive option that seems to reside the most Convincing opportunity for the emergence of anew Paradigm in building construction. In the history of ‘architecture, there are plenty of examples in which buildings were made out of structural surfaces (Ge. in stone or concrete). However, the ability to <éesign and fabricate using CADICAM allows one to extend the implicit geomotric challenge Into a higher degree of complexity. But, to really achieve ‘a new stage in builaing design and construction, the recent contribution of computer aided engi- neering technologies (CAE) in the process should ‘also be integrated and further explored. Infact, by Using three dimensional components, the thiok- ‘ness propery introduces a dimension where dig tally controled performance can be introduced. In this context, imovative structural surfaces can ‘emerge by rolating complex geometries with the adaptive play of diverse and measured functional roles (ie. structural, thermal and acoustic insule- tlon, waterproof, ornamentation, etc). This cond tion of convergence between geometry and perfor- ‘mance can only be designed, analyzed, evaluated ‘and fabricated with the help of cota technology. 226 | eCAADe 23 - session 5: fabrication 3. Final Remarks ‘The analysis developed in chapter2, llustates the problem identified in the first chapter. It evi ences that there are ambiguous promises asso- Ciated with the integration of new technologies in architecture, as thei real application in practice is not so straightforward or innovative as sometimes itis presented. One possible explanation is thatthe ‘expectations behind the exploration of CAD/CAM processes in architecture migrate trom other de- signtelated areas during technological transier- fence processes. However, the specific natura of architecture Introduces certain factors that con- strain the real effectiveness of these approaches and early optimism. in other words, architecture's capacity to engage these technological possibil- ties is naturally diferent from other disciplines. For Instance, although the exploration of formal com- Plexty implied in the design of an airplane and in the design of a building can be compared, the product ofthe aerospace industry, once Itls devel ‘oped, it becomes a standard model ready to be re- produced, while buildings usually consist in unique products. This condition Implies clear dtferences Inthe economic supports involved in the research and development efforts in these industries. On a diferent level, the scale associated with product design industries permits the feasible exploration fof mase-customization procedures as many ofits products are composed of few, small components. Inan extreme case, inthis industry there are prod- tcts that consist in a unique part fabricated with a single machine. Given that architecture is a large ‘scale and complex assemblage of components, the mass production of variation reaches a higher ‘degree of complexity. Thus, it might be wise to rec- ‘ognize that architecture cannot engage in all the theoretical challenges proposed by new technolo- ies in the same ways as other industries, other- Wise there is the risk of generating a misleading discourse on this subject. ‘To move beyond some of the existent limitations and challenge conventional building para- digs with new technologies, architects may need to.g0 beyond the role of “importers” and “users ‘Tho stratogic combination of avaliable fabrication processesis interesting and can be adjusted to the ‘specificities ofthe discipline but, at the end, it da- fines a limited horizon of progression, constrained by developments that take place in other indus- tries. The stepping forward that has already hap- pened in the level of CAD, with architeots exploring ‘advanced modeling techniques and programming customized applications, should now happen at the lovel of fabrication. This does not mean that all practitioners should engage in this effort but that It is necessary to guide research on this level to- Wards specific interest of architecture. Some initia- tives are already in progress lke the contour crat- ing technology developed by Behrokh Khoshnevis at the University of Southern California, or the huge CNC milling machine involving molds made by earth envisioned by Wiliam Massie. itis time for academic research resources and architect's ere- alive minds to play a more decisive role inthe di velopment of digital technologies. The answer for ‘more efficient and flexible processes of translating architectural ideas into physical constructions can possibly come from the discipline of architecture Itsot. Acknowledgments ‘This paper is part of the first author doctoral research In Engineering Science at IST-UTL, which investigates how the tectonics of traditional mate- fials can been expanded by means of distal pro- ction technologies. This work has been support- ed by the Portuguese Foundation for Science and Technology (FCT). The authors would lke to thank Professor Detlef Mertins for supporting the visiting ‘scholar period at University of Pennsylvania which was Important for developing some of the ideas In this paper, to Branko Kolarevic for sharing his ‘experience and thoughts in informal conversations ‘on the subject of CAD/CAM technologies and to Marta Malé-Alemany for her constructive discus- sion and advice regarding the topies ofthis paper. References Bechthold, M., Griggs, K., Schodok, D. and Stein- berg, M., Eds.: 2001, New Technologies in Ar- cchitecture |, Harvard Design School, Cambridge Ma. Bechthold, M., Griggs, K., Schodek, O. and Stein- berg, M., Eds.: 2003, New Technologies in Ar- chitecture Il & Il, Harvard Design School, Cam- bridge MA. Beesley, P, Cheng, N., Williamson, R. S., Eds. 2004, Fabrication. 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Blobmelster First Built Projects, Birkhauser, Berlin, ‘Schodek, D., et al, Eds.: 2004, Digital Design and Manufacturing: CAD/CAM Applications in Archi- tecture and Design, John Wiley & Sons. ‘Shelden, D.: 2002, Digital Surface Representation ‘and the Constructibiliy of Gehry’s Architecture. Pho. in Architecture, Design and Computation, Massachusetts Institute of Technology, Cam- bridge MA. session 5: fabrication - @CAADe 23 | 227Yun, ¥. G: 2001, Structural Composite Members in Architecture Fabricated by CADICAE/CAM Technology, Doctor of Design Thesis, Gradu- ate School of Design, Harvard University, Cam= bridge, MA. 228 | eCAADe 23 - session 5: fabrication