Construction Improvements for the Making of Free-Form Surfaces

CAD/CAM
1.CNC
(Kolarevic,2003) 2. (Welch,1994; Turkiyyah, 1997 ; Lee,
2005 ) 3. ( Glymph , 2002; Shelden,2002 ; Schmiedhofer, 2008)

CNC

(LIM,
2006; Lee,2005 ;Turkiyyah ,1997)

( Shelden,2002 ;
Schmiedhofer, 2008 ; Baldassini, 2008)

1.
2. 3.

1: (U,V)
2: U,V

3: sweep NURBS
4: Form Finding Shelden,2002

5:
6:

53
41 24

50%

I
 The development of computer technology and new media in architecture has given new
rise to the creativity of designers and lead architecture to new break through in construction. The
making of CAD/CAM free-form structures, can be divided into the making of curved surfaces
and the skeleton. In using curved glass as the skin, methods often used are: 1. CNC for the
making of curved components (Kolarevic, 2003) 2. Triangulating curved faces and then
flattening (Welch, 1994; Turkiyyah, 1997; Lee,2005) 3. Quadrilateral Planar Facets. (Glyph , J.
2002;Shelden, 2002 ;Schmiedhofer,2008) This research paper proposes a new method for
curved-glass construction using a simple and robust geometric method.
Presently, problems encountered while making CAD/CAM surfaces are view in two dimensions:
1. Manufacturing issues: In present manufacturing, each unit is unique and needs to be made
individually. Such complexity leads to problems like mounted expenses and difficulties in
construction. ( LIM , 2006 ;Lee,2005 Turkiyyah ,1997) 2. Aesthetic issues: Triangulating , and
parallelogram framing techniques form shapes out of planar components. This constructs a
non-smooth surface for the exterior causing it lose aesthetic values.
( Shelden,2002 ;Schmiedhofer,2008 ;Baldassini,2008)Therefore, the main problem is: in order
to minimize changing the original design during construction and to construct in a simpler
fashion, how do we maximize the amount of repeated components but at the same time keep the
smoothness of the free form design?
According to the problems mentioned above, we review actual cases on curtain glass, and
then demonstrate the geometric method through procedure. At the end process and steps will be
categorized and organized into a framework for free-form glass dividend. Free-form surfaces
mentioned in this paper are to meet the restrictions: 1. free-form surface must be a glass curtain
2. curved surface must be curved in both directions. 3. the surface component is to be a curved
surface which has a constant radius of curvature. The geometric method proposed in this
research, uses a curved surface to meet the original designed shape allowing surface components
to divide surfaces into repeated components. Procedure can organized as below:
Step 1:To use a double dimension (U,Vdimension) degree 2 curve as a control element for
NU RBS.
Step 2:By adjusting the control element we execute form-finding on the “ main 3D model”
for a shape-closure to the original form. The new shape will come close to the
original and thus replace it.
Step 3:Then, divid the curved surface to while conforming these two control elements.
Step 4:Part of the new curved component will grow symmetrically due the the symmetry of
the curved line. Resulting from this symmetric, paired and identical curved
components will be found in the new shape.

The new surface constructed using this method will result in a smooth surface along with a
few repeated curved components. However, this inevitably will slightly change the shape of the
original design. Under ideal circumstances, curved components can be reduced to half the
original design.

II
 I

II

III

1. 1

1.1. 1

1.2. 3

1.3. 5

2. 8

2.1. 8

2.2. CAD/CAM 11

2.3. 13

3. 21

3.1. 22

3.1.1 22
3.1.2 FORM F INDING 25
3.1.3 CAD/CAM 28

III
3.2. 32

1 33
2 37
3 UV NURBS 39
4 F ORM FINDING 40
5 41
6 43
3.3. 45

3.3.1 45
3.3.2 CAD/CAM 48

4. 51

4.1. 51

4.2. 52

4.3. 53

5. 55

IV
 1.

1.1.

(Liu, 1996; Porter and Neale,2000; Smith, 2004)

(Mitchell, 1998.b Nardini, 2003 Kolarevic, 2003)

20
(Mitchell, 1998.a Liu, 2001 ,Liu, 2008)

(Mitchell, 1998.a Ruby, 2001)

CAD/CAM
(fabrication) CAD/CAM

(Mitchell, 1998)CAD/CAM
tectonics
(Gao, 2004; Liu and Lim, 2008 )
CAD/CAM

1
 (Kolarevic , 2003 LIM,2006 Lee,2005; Turkiyyah,
1997 ;Schmiedhofer;2008)

CAD/CAM
monocoque construction

(Shelden,2003; ,2005 ;Griffith and Kenfield,2006)

(Glymph, 2002 ; Shelden, 2003 ; Kolarevic,

2003 )

CNC milling
CNC
milling
smooth
Gehry Conde Nast
Bernhard Franken 1999 BMW
( 1-1)

(Turkiyyah et al., 1997;Welch,1994)

Shelden,2003;
Schmiedhofer ,2008 3D
2D 2005
CAD/CAM

2007 BMW
( 1-2)

2
 Catia (Glymph, 2002 ; Shelden,
2003)
( Schmiedhofer,2008; Pottmann et al,2006; Baldassini,2008 ;)

2007
Norman Foster
1-3 (Schiftner, 2007)

1-2 1-3
1-1 CNC milling

1.2.

(Lynn, 1995)

(Glymph, 2002; Shelden,2003; Kolarevic,2004)

CNC

(LIM,2006 ;Lee,2005 ; Turkiyyah ,1997)

3
 1-1 ( Shelden,2003 ; Schmiedhofer, 2008 ; Baldassini, 2008)

1-1

CNC

G0
( )
G1 G2
1-4

4
 1-4 A G0 B G1 G2

1.3.

CAD/CAM
CAM

1.1

Ruled Surface

1.2

5
 1 2 3

CAD/CAM

1.3

2002 Dennis R. Shelden

2007
(continuity)

2.1

2.3

6
2.4

3.1

(G2 )

3.2

7
 2.

2.1.

2.1.1 -

( Zevi , 1981;
, 2006) Schon 1992

1900 Estereo
Estatica Utzon
(Million, 1994

8
 (Kolarevic,
2003; , 2006)

CAD/CAM

(Mitchell, 1998;Kolarevic, 2001)

2.1.2 -

1900 2000
( , 2006 )

2D

1900 Casa Milla, Colonia, Sagrada Famili

Le Corbusi 1924 Erich Mendelsohn

Rudolf Steiner 1928s ( 2-3)

(Steiner,2003 Liu 2006

Lim2006)

1950

9
 1957John Utzon Sydney Opera House( 2-2)

Utzon

2-1 2-2 2-3 Rudolf Steiner

CAD/CAM

CAD/CAM
2D

CAD/CAM
CAD/CAM (Kolarevic, 2001; Mitchell, 2004; , 2001; 2005;
2007.)
( , 2003)

CAD/CAM

1997 Frank Ghery

CAD/CAM
3d Scanner
RP Ghery

10
 Catia CAD/CAM GT ghery tecnolige
NOX Frankert UN studio Zaha
CAD/CAM

2.2. CAD/CAM

2.2.1 CAD/CAM

1950 SAGE

(plot) 70

1. Mesh ” ” ” ”
2. 3D
3. ”(non-uniform rational B-spline, NURBS) CAD
CATIA
4. (Solid modeling) I-DEAS Unigraphic
UniSolids (CAD CAD-History) (Chris and Jimmie, 1993)

70 CAD/CAM CAE (Computer-Aided

Engineering, CAE)
CAD/CAM
CNC (Callicott, 2001)
CAM CAM
1980 CAD CAM
(Groover and Zimmers, 1984;Mitchell and McCullough, 1995; Ryder et al, 2002)

1. CNC (computer numerical control, CNC) (subtractive)

(a).3D CNC milling (b) (CNC water
jet cutting) (c). (laser cutting) (d) (CNC routing)

11
2. RP (Rapid Prototyping, RP) (Layered Manufacturing,
LM) 1.Concept Modeling
2.Rapid Prototyping
3. 3D scanner:
CAD (Luca and Nardin ,2002) (Seely, 2004;Friedman, 2002)

2.2.2 CAD/CAM

(Shell)

(Sapaun ,2005)
2-4 1957 John
Utzon ( 2-2)
2006

2-5

2-4 2-5 2006

(monocoque construction)

(Lynn,1995)

monocoque construction
Monocoque Mono coque

12
 (Shelden2002; 2005, Griffith2008)

2-6 2-7

2000
Jennifer ,Seely, Kolarevic 2003
2006 CAD/CAM
Gehry Franken
1. 2. 3.
4. ( 3-1) (Mitchell, 1998; Lindsey, 2001;
Kocaturk 2001; Kolarevic, 2003; Dritsas, 2004; Lee, 2005 ;Lim,2007)

2.3.

(Glymph,2002 ;
Shelden,2003) CAM
1.CNC Kolarevic, 2002 2.

13
 CAM

CAD 1.
;
2.

Glymph,2002;
Shelden2003 ; Schmiedhofer,2008

2.3.1 CNC milling

CNC milling

CNC milling
CNC

RP
CNC
CNC milling
Seely, 2004

CNC milling Frank Gehry

1997
CNC milling
( 2-8) (The Walt Disney
Concert Hall, 1992-97) CAM 3D CNC
milling

14
 2-11 2000
Frank Gehry Conde Nast Cafeteria CNC milling
2-10
Gehry CNC
Franken, 2003)

2-8 CNC milling 2-9 Walt Disney Concert 2-10 CNC milling
Hall

2-11 CNC milling ( Kolarevic, 2003)

1999 BMW Bernhard Franken “ ”

3D

3500 CNC milling 305

(Franken, 2003) 2-12

2-12 Bernhard Franken (1999)BMW (Franken 2003)

15
2.3.2

( 2-11) CAD/CAM
3D 2D

NURBS
Subdived( )

(Glymph et al,2002;
Shelden, 2003;Schmiedhofer ,2008)

Welch 1994
1997 Turkiyyah

2-13

CAD
Form Z
Peper kura
( 2-15)

3D 2D ,2005
CAD/CAM

( 2-14)

16
 2-13 2-14 2-15 Peper kura
(Welch,1994 ,2007

2000 AleppoZone

Laser cutter
( 2-16) Liu et al ,2002 Lim ,2004 ,2005
Massimiliano Fuksas2004 Milan Trade Fair
( 2-17)2007 BMW
Laser
cutter 2D ( 2-18)

2-16 2-17 Milan Trade

2-18 2007 BMW

17
2.3.3

CAM

2D

2-19 (Pottmann et al,2006)

(Glymph et al, 2002 ; Shelden,

2003;Pottmann et al,2006; Schmiedhofer,2008)

2-19

2003 Dennis R. Shelden

2008 ,
PQ meshes PQ meshes:

18
 ( Schmiedhofer , 2008 )

2002 Simon Wiesenthal Center

7
( 2-20) 2004 Norman Foster
Sage
(Schiftner, 2007) 2-21

2-20 Simon Wiesenthal Center 2-21 Sag

2.3.4 Quadrilateral Planar Facets

2002 Dennis R. Shelden

19
 Translation Surface

Catia

( 2-22,2-23)

2-23
2-22 Quadrilateral Planar Facets

20
 3.

CAD/CAM
2007 ( ,2005)
CAD/CAM

CAD/CAM 3D
(
3-1)

3-1 ( ,2007 )

21
 CAD/CAM

RP
3-2

3-2

3.1.

3.1.1

G1 G2

1909 Edouard Benedictus

22
 , 26:

. . :
:

3-4
3-3

( 3-3,3-4)

1.
Rule surface

23
2. .

NURBS

G0 :
(G0) ( 3-5a)

G1 :
( )
(G1) G0 ( 3-5b)

G2 :
(G2)
G2 G0 G1 ( 3-5c)

3-5A G0 3-5B G1 3-6 G2

24
 G0 ( )
G1

3.1.2 Form Finding

2003 Dennis R. Shelden

Generatrix Directrix sweep

(GLYMPH,2002; Shelden, D, 2003;Pottmann et al2006;

Schmiedhofer,2008)

Shelden Shelden

G1
Generatrix directrix surface
( conical
line) ;

( )

( 3-7)

Generatrix
directrix Form Finding

25
 3-7 UV : Gene1 ratrix Directrix :
Unite Unite 1’

NURBS
B-spline
Non-Uniform Rational B-Spline NURBS
NURBS
( Degree )

y = 3·x3 –2·x + 1 " "

3·x3 –2·x+ 1 3 –x5 + x2 5 NURBS
NURBS NURBS (
–1 ) ( Span ) " " 1
" " 0 "( 3-8) ( )
2 " " 1 ( 3-9) 3 3
Z " “( 3-10)

0
1

26
 2

3-8 1 3-9 2 3-10 3

Conical Line

conic section
3-11

(generator
line)

F( ) F
L( ) e( ) F
e L 0<e<1 e=1
e>1 ( 3-12) e=0
L e

Form Finding

27
 3-11
http://mathworld.wolfram.com/
3-12

3.1.3 CAD/CAM

CAD/CAM
MAYA RHINO 3DsMAX INSIGHT ( 3-13)
CAD/CAM

3-13 CAD/CAM

CAD

CAD/CAM
CAD CAM

CAD/CAM

Rhino

NURBS
B-spline Non-Uniform
Rational B Spline POLYGON NURBS
(Mesh)
NURBS

28
 NURBS
NURBS
NURBS

3D Rhino4 CAD NURBS

Rhino NURBS Rhino
Rhino IGES
FBS STL file
Rhino Rhino4
3DsMAX Form Finding

3DMAX

3DMAX NURBS
3DMAX NURBS STL.file

1. Approxima tion/Tessellation NURBS

2. Tramsfore Degree

3. 3DMAX NURBS 1Rail-sweep Sweep Parallel

Rhino
Sweep1 Rhino Form Finding

STL.file

NURBS STL 3dsMAX STL

Insight STL 3dsMAX
STL

1. RHINO STL Mesh NURBS

RP
STL MAX

2. POLYGON 3dsMAX Convert to POLYGON

STL

29
 Edit polygon/Polygon/Flip
( 3-14)

3. RP Shell
Polygon RP
1mm ( 3-15)

4. STL STL check 1. Open

Edge Edit polygon/Border Edges (CAP) 2. Edit
Polygon / WeldVertex ( 3-16)

3-14 3-15 SHELL 3-16 STL.file

Insight

Insight CAD CAM 3dsMAX

STL RP
Insight ( 3-17)

1. slice STL STL/ Units and scale

(Slice height)
RP
( 3-18)
2. (Modelers Setup) (Solid)
(Sparse)
Fine rasters)
( 3-19)
3. (Toolpaths)

30
4.
STL
Insight
3dsMAx STL Insight

RP

3-17 Insight 3-18 3-19

CAM

RP (Fused Deposition Modeling, FDM)

3-20 Insight 2D
3D RP

RP
Insight

3-21

3-20 RP 3-21

31
3.2.

2007
2010
20 150

AleppoZONE

1-2 28
16
2-3 ( 3-22)

3-22

RHINO 4

1: (U,V

2 U,V

32
 3 NURBS

4: Form Finding

6:

1.1

3D
3D

MAYA
MAYA NURBS
RHINO4
MAYA IGES (3D )
(smooth) (optimized) CV

33
 CV 3-1 UV
CV 3519 99.14

1/15
( 3-23 ; 3-24) 3-2:

3-1

NURBS NURBS
U: = 3 CV = 153 (0 <= U <= 1) U: =3C
V: = 3 CV = 23 (0 <= V <= 2) V = 10 (0 <= U <= 1)
CV 3519 CV 30
4 4

3-23 3-24

34
 3-2 1.1

MAYA Export
IGES

RHINO MAYA IGES

Untrim

CurvatureAnalysis

Properties/ Detail/ Object Description

CV
3-1

35
 Rebuild

1.2

NURBS
NURBS ( Degree )
(CV) ( Knot )

3-10 UV
NURBS

UV

3-3

3-3 1.2

ExtractIsoCurve
ExtractWireframe

36
Section

conical
surface NURBS surface

Mesh Mesh
NURBS

3.1.2

3-4

RHINO
Trim
3-25-a

37
 G1 3-25-b

4 5
3-25-c-d

3-25 : A B C
D

3-4 2

2 ChangeDegree

38
Rebuild Curve
4

PointsOn

Conic

PointsOn

3 UV NURBS

UV 2002 Dennis R. Shelden

UV UV
3.1.2 Rhino Sweep1
Formding
3DsMAX UV 1Rail-sweep
Sweep Parallel Tramsfore Degree
Surface Approximation/Tessellation/Hight
3-5

39
 3-5 3 UV NURBS

3DsMAX

1Rail-sweep

MAX
NURBS LATHE
1Rail-sweep

1Rail-sweep
Sweep Parallel

4 Form Finding

UV

Form Finding
surface UV

3-28-C

3-6

40
 3-6 4 Form Finding

CV

Pull

IGES rhino

DupBorder

Trim

5.1

41
 ( 3-27) 3-7

3-7 5

Section

3-3

42
 5.2

( 3-26)

2 :

( 3-27

3-26 3-27

3-8

( 3-28)

43
 3-28

3-8 6

DupBorder

BlendSrf

5-1
Trim 3-3

44
3.3.

3.3.1

sweep

54
( 3-9)

3-9

53 24

19

19

11

45
 Zebra

(G2)
3-29

3-30

3-29 (G2) 3-30

2003 Shelden
UV

46
 NURBS

RHINO Area 3-10

RHINO PointDeviation 3-31

3-31

3-10

2266829 : 17.4852 : 15.6658

2273601 17/755= 2.25%

100.4% : 72.8582 72.8/2836cm = 2.57%

47
 3 Degree 2
2
1

Form Finding

3.3.2 CAD/CAM

3 CAM CAD/CAM
3-1

CAM 3d
CAM
CNC
RP ABS 3-32

3-32

3d RP CAM

48
 ( 3-33)

Bently Micostaion

( 3-37)

3-33 3D

RP 3-3
RP
1 2 3( 3-34
)

RP

1 2
3 RP

1: 3d 1

2:
2 1 4

49
 3 7

( 3-34 )

CAD/CAM

CAD/CAM
Form Finding 3D
RP
5
( 3-35)

3-34 RP

3-35

50
 4.

CAD/CAM

4.1.

CAD/CAM

CAD/CAM
CNC Milling

3-1
3-2

51
 CAD
1 6

1/2

1- 6

50% 3-9

3-30

3-10

CAD/CAM CAD/CAM
Rhino 3ds Max

RP
RP CAD/CAM
3-35

CNC milling

4.2.

52
 2003 Dennis R. Shelden

5
2

Pattern

1/2
2

3.1.1

Rule surface

2006 CAD/CAM

4.3.
4 Form
Finding 2 5

3-3

53
 CAD/CAM
Rhino MAX

Ruled
surface

54
 5.

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, 2005. (A study on the process of free form design and

construction)

, 2007. (A better digital design and construction process using

CAD/CAM media)

, 2001. , ,

. (ed.): 2006,

( ), 2003. , ,

The History of CAD http://mbinfo.mbdesign.net/CAD-History.htm

Rapid Prototyping http://check.itgo.com

OpenNURBS http://www.opennurbs.org/

Mathworld http://mathworld.wolfram.com/

57