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Self-shaping systems offer a promising approach for making complex 3D geometries from the material-driven transformation of 2D sheets. However, current research development of such systems is focused on small-scale applications. This study proposes a self-shaping composite for generation of larger-scale curved surfaces suitable for spatial structures. The composite arises from the novel combination of a perforated plate passive layer and a heat-shrinkable active layer. Experimental investigations are undertaken to assess the influence of perforation parameters of the passive layer over the degree of curvature generated in the self-shaping composite system. A 3D scanner and parametric curvature evaluation tool were used to extract and analyse the fabricated surface curvatures. Three key deformation characteristics were identified: the generated surface is cylindrical with dominant curvature in the x-direction; curvature is approximately uniform across the surface width and length; and curvature is strongly influenced by perforation bridge and strap length parameters. Results of this study support the application of self-shaping curved surfaces for customizable discrete structure parts.
Self-shaping systems offer a promising approach for making complex 3D geometries from the material-driven transformation of 2D sheets. However, current research development of such systems is focused on small-scale applications. This study proposes a self-shaping composite for generation of larger-scale curved surfaces suitable for spatial structures. The composite arises from the novel combination of a perforated plate passive layer and a heat-shrinkable active layer. Experimental investigations are undertaken to assess the influence of perforation parameters of the passive layer over the degree of curvature generated in the self-shaping composite system. A 3D scanner and parametric curvature evaluation tool were used to extract and analyse the fabricated surface curvatures. Three key deformation characteristics were identified: the generated surface is cylindrical with dominant curvature in the x-direction; curvature is approximately uniform across the surface width and length; and curvature is strongly influenced by perforation bridge and strap length parameters. Results of this study support the application of self-shaping curved surfaces for customizable discrete structure parts.
This paper illustrates the design and fabrication processes of the Hypar Up pavilion, which served as a proof-of-concept to demonstrate the viability of a design-to-fabrication workflow for complex yet modular architectural geometries that utilise small and planar timber offcuts geometries discretised as Planar Quadrilateral (PQ) meshes. By integrating computational design and optimisation with efficient manufacturing processes, this research highlights the technical challenges of repurposing materials with unknown characteristics, notably detailing solutions, and evaluates the efficiency of design-to-manufacturing workflows with surplus timber products, using a quantitative cost analysis of the fabrication and assembly phases. While exploring the potential of repurposing scrap wood into hypar-shaped modular construction components, this work expands on existing research on segmented shells and investigates methods and means to move beyond the use of shell structures as monolithic and static artefacts. The pavilion is intended as a 1:1 modular prototype that can be resized to accommodate different dimensions of the timber panel offcuts and potential applications to be tested in future applications, such as load-bearing walls and facade retrofitting.
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