Closing the Links. Free-Form Timber from Design to Production

Closing the linksfree-form timber from design to productionClosing the linksfree-form timber from design to production

Fabian ScheurerFabian Scheurer

projectsworkflowchallengesfuture

26 september 2014 2forum holzbau nordic

Bild: ContecBild: Contec


Camera obsucra trondheim 2006ntnu: 1-2-tre, prof. larsen

Bild: ContecBild: Contec


Swissbau pavilion basel 2005eth zurich, professur für caad

Bild: SJB Kempter FitzeBild: SJB Kempter Fitze


Centre pompidou metz 2010shigeru ban & jean de gastines


1800 curved beam segmentsincluding all connection details

Bild: Blumer-Lehmann AGBild: Blumer-Lehmann AG


nine bridges golf club yeoju 2009shigeru ban & kaci international



3 500 curved glue-lam segments…



…assembled to 32 elements…



…resulting in 2 500 sqm roof structure


Image: Blumer-LehmannImage: Blumer-Lehmann

Bild: Tuomas UusheimoBild: Tuomas Uusheimo


kilden performing arts center kristiansandala architects, 2012

Bild: TrebyggerietBild: Trebyggeriet


300 straight + 1700 curved beams…



+ 12 500 oak-boards…



= 126 pre-assembled façade-elements…



= 3 500 sqm oak-facade


Image: Tuomas UusheimoImage: Tuomas Uusheimo


hermés rive gauche paris 2010rena dumas architectures intérieures


Snaporaz sculpture zurich 2012marco ganz


D1-tower canopies dubai 2012innovarchi architects


mobiversum wolfsburg 2013jürgen mayer h.


Carnal hall rolle 2014bernhard tschumi


french pavilion expo milan 2015x-tu architectes


Swatch headquarters biel 2017shigeru ban architects


pre-fabricated componentscomplexity is handled off-site


«mass-customization»bespoke at serial cost

Bild: Blumer-Lehmann AGBild: Blumer-Lehmann AGBild: Blumer-Lehmann AGBild: Blumer-Lehmann AG


digital fabricationprecision and efficiency at lot size one

Workflowshift towards planning


fabrication assemblydesign planningpre-

assembly(off-site)

more individual parts (lot size one)

increased level of detail(cnc-fabrication)

planning

dataflowdigital model at the core


design(architect)

engineer fabricator

parametric3D-model

reference geometry

model + data

fabricationdata

details + dimensions

fabricationmethods


1. design inputhas to match fabrication tolerances.

design model parametric model D

E F

M


10 meter long beamsmilled to 0.5 millimeter perfection


Connection detailsproduced on the same machine


centre pompidou metzthe intention of shigeru ban


input for the timber fabricator:points and lines in a dxf-file


reconstruction of «design-surface»as a continuous nurbs-surface


haesley nine bridgesno «trees» but «crowns»


reference geometry «on a napkin»no 3d-model, just a few numbers

reference geometry usually has to be re-built to match requirementsa concept on a napkin is better than a digital point-cloud

modelling precision has to match fabrication precisionfree-form geometry requires free-form-models (no meshes)

we use a NURBS modeler instead of standard timber CAD software…until they can handle real free-form geometry

link#1: design input fabrication model


D

E F

M


2. everything that has to be digitally fabricated has to be digitally modeled first.

parametric detailing D

E F

M


this is not a beautiful node…

Image: Rensteph Thompson / Hess TimberImage: Rensteph Thompson / Hess Timber


…unless it’s assembled


up to 450 machining operationson a single component…


…× 250 components with 200 joints=14.000 holes, slots, pockets etc.


digital parametric modelingprogramming instead of drawing

amount of bespoke parts and details requires parametric approach

programming instead of drawing systematic solution

parametric detailing requires to resolve the worst cases firstsolving the easy nodes first results in a multitude of different details

we program project-specific CAD-tools… as plugin-ins on the basis of standard software

link#2: parametric detailing


D

E F

M+


3. file to factoryis far from automatic as soon as you’re off the beaten track.

parametric model fabrication data D

E F

M

file-to-factory(marketing view)


CAM CNCCAD

Seite 54

Works on a model scale3d-printer

26 september 2014 forum holzbau nordic


Who fabricates what when and where?just in time fabrication on different machines


Complex componentswhich cut first? from which side?


Complex operationswhich tool?

26 september 2014 Seite 58forum holzbau nordic

Complex raw materialeven the blanks are custom made


Complex featuresCAD to CAM

Simple featuresautom. «Feature Recognition»

Complex features:Manual programming

«Feature Recognition»+ manual assignment

«Custom CAM-interface»Project-specific interfaces toCAM-system in collaborationwith fabricator

«Custom Post-Processor"project- & machine-specificinterfaces directly down tothe machine

CAD to CAMwithin one project


file-to-factorystate of the art


Parametric

CAD

CAD/CAMcustomimport

ExtendedGeometry

(3dm)

CNC

G-codeFinal

geometry(dwg, sat)

CAD/CAMfeature

recognition

G-code(iso)

G-code

Blank+features

(BTL)CAM G-code

Design

CAD

Automatic feature recognition only works for simple cases… not for non-standard parametric detailing

Project specific CAM-interfaces require a counterpart on the CAM side… usually someone with programming skills at the fabricator

Project specific post-processors are costly and machine-dependent… and only make sense in large projects

we aim at machine-independent CAM-formats (like BTL)… where we can create fabrication-data directly from the 3D-model

link#3: cad cam


D

E F

M+ btl


BIM to fabrication?

BIM-Model Fabrication Data


scalabilityamount of data grows in two dimensions

0

5

10

15

20

25

0 5'000 10'000 15'000

deta

ilspe

r com

pone

nt

number of components



parametricshow to describe rules and dependencies?

architecture

engineering

detailing

sourcing

fabrication

logistics

assembly


integrationhow to organise workflows?

Seestrasse 78 CH-8703 Erlenbach/Zürich T +41 44 914 74 90 F +41 44 914 74 99 www.designtoproduction.com

let’s get started…

Fabian Scheurer [email protected]

www.freeform-timber.com

Closing the Links. Free-Form Timber from Design to Production

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