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FREEFORM CONSTRUCTION DESIGN

Developing Advanced Manufacturing Technologies For Innovation in Construction: Architectural Freeform (ArchiForm)

Simon Austin, Dino Bouchlaghem, Alistair Gibb, Christine Pasquire, Martyn Pendlebury, Tom Modeen, Rupert Soar, Tony Thorpe.

Loughborough University IMCRC, BPB Plc, Z-Corp Inc., English Heritage.

 

 
 
     
 
 

 

  BACKGROUND


Freeform Construction will release many of the constraints on the design and construction process.  It will give architects the freedom to design organic forms and structures for everyone.  This isn’t about exclusivity or grand statements and edifices, it’s about how our homes, our offices and factories, will look and function with stunning architecture, organic forms and individuality defined and selected by the client.  Architectural Freeform (ArchiForm) is about raising the construction industry’s awareness to the potential of freeform construction by identifying readily transferable projects where Rapid Manufacturing can be applied to construction practice and the design process.

 

OBJECTIVES

The research has a range of avenues which are being pursued through the multidisciplinary team of researchers, academics and companies involved.   At one level it will identify a methodology for fabricating architectural designs, through freeform construction. The approach is an analysis of the perceptual spectrum as an essential ingredient in the conceptualisation and realization of a design (be this a product, a piece of furniture, or a building). It is built around a predetermined design that has been conceived and selected by consideration of the capabilities which Rapid Manufacturing will bring to the construction process. In this instance, the design selected is an adaptable and perceptually responsive surface called ‘Design Ground’.  Being able to manipulate the consistency of a fabricated material, changes can be made to the components tactile and even auditory qualities.  By making the surface more or less dense, and by patterning the surface according to various utility and performance based configurations, one can make the surface ‘feel’ and even sound different (e.g. when walked upon) at various locations.

 

   
 
 
   

 

 

 

 
 
 

 

On another level, the research will consider the customisation of parts and components for those industries which produce traditional or heritage products for which existing Rapid Manufacturing techniques are readily transferable.  The work will assess the viability of freeform construction whilst identifying the limitations and cost implications, of applying these techniques, to the broader construction industry. The aims of this aspect of the research are:

 

        Identify and test end user/client customisation using freeform construction and reverse engineering, focussing on the repair and refurbishment of architectural detailing in Heritage Buildings.

 

        Identify preliminary architectural, structural and services engineering limitations to volumetric freeform construction, propose solutions to these and test through theoretical and physical modelling.

 

         Investigate the business case behind the examples proposed in (i) and (ii) across the supply chain clearly identifying benefits and constraints for the parties concerned.

 

Specifically, the research is looking at the scanning/digitizing of Heritage components, such as damaged plaster reliefs. Damaged sections will be scanned either in-situ or within the laboratory and the data repaired using ‘haptic’ devices for freeform image manipulation to rebuild the damaged section.  The repairs will be converted into either ‘crowns’ or as complete gypsum pieces generated using a range of current Rapid Manufacturing processes, including the Z-Corps large format 3D printing process. 

 

Please click HERE for contact details.

 

Please click HERE for sponsor and collaborator details.

 

© 2005 Rupert Soar. All rights reserved.