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MAS Digital Fabrication

​

​

# Caschlatsch

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Gramazio Kohler Research, ETH Zurich

​

Prof. Matthias Kohler, Prof. Fabio Gramazio, Petrus Aejmelaeus-Lindström (Project Lead), Oliver Bucklin (Research Lead), Ananya Kango, Simon Griffioen, Francesco Milano, Aurèle Gheyselinck, Alexandra Moisi, Joseph Kenny, Chen Kasirer, Gonzalo Casas

​

RFL Team: Michael Lyrenmann, Phillippe Fleischmann, Luca Petrus, Tobias Hartmann, Jonathan Leu

​

MAS ETH DFAB Students: Amir Ali Amini-Aghdam, Benhur Baiju, Chia-Hsuan Chao, Joana Francisco Tomaz, Hamid Peiro, Junjie Huang, Paul Jaeggi, Jiaxiang Luo, Giacomo Montiani, Wataru Nomura, Panayiotis Papacharalambous, Sukhdevsinh Parmar, Kevin Seav, Gonzalo Seminario Garcia, Megi Sinani, Namdev Talluru, Kai Hsun Yeh

​

In collaboration with: #dfdu AG (Stefan M. Seydel), Studio UH Architects ETH SIA, Nicolas Fehlmann Ingénieurs Conseils SA

Client: Gemeinde Disentis/Mustér

�Selected Experts: Bearth Lenn AG, Strabag AG Disentis/Mustér, Prof. Daniela Mitterberger (COMPAS_XR), Ziqi Wang (Task Sequencing and Allocation)

​

Sponsor: Schilliger Holz AG, Bearth Lenn AG, Strabag AG Disentis/Mustér, Nicolas Fehlmann Ingénieurs Conseils SA, SFS Group Schweiz AG

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Background Research

COMPAS Framework

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Background Research

CAD Independence

Data Management

Geometry Processing

COMPAS Core

​

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…

STP

OBJ

IFC

JSON

…

BRG

GKR

DBT

…

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Background Research

COMPAS extensions

​

compas_3gs

compas_ags

compas_tna

compas_cem

compas_dr

compas_dem

compas_cra

compas_tno

compas_rbe

compas_3dec

compas_prd

compas_slicer

compas_fab

compas_rrc

compas_vol

compas_fea(2)

…

compas_timber

compas_ifc

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Design

Analysis

Planning

Fabrication

COMPAS Timber

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Background Research

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COMPAS Fab

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Background Research

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COMPAS XR

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Background Research

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Making complexity less complicated through computational tools

​

​

​

Background Research

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Intro: T2 Project

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Intro: Disentis / Mustér

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

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Monastery

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Disentis/Muster

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Ruina Caschlatsch

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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east-west section of site

north-south section

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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  • timber volume limited to 10 cubic meters maximum
  • design should be segmented into modules to fit within a truck
  • maximum length for a beam not to exceed 5 m
  • minimum beam dimensions not under 60x60mm cross section
  • each module weight not to exceed 800 kg

Constrains

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Exploration: Typologies

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Tower

Exploration: Typologies

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Surface based

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Exploration: Typologies

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Volumetric

Enclosed structure

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Initial Frame

Stabilized Element

Infill Element

Exploration: Typologies

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compas_timber

JSON Building Plan

BTLx data to .hop for beam processing

Robot Movements

AR Assembly Guide

Multi-user fabrication

Milled beam elements

JSON print data

Printed facade elements

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Design Workflow: Process

1. GLOBAL DESIGN

2. CLUSTERING

3. STRUCTURE & INFILL

4. JOINS and ASSEMBLY

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Design: Global Design

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Voxel

Assembly Module

“Air” Module

(800 kg max. per flight)

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Ruina Caschlatsch

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

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02 Existing trees to be removed

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Project location

Ruina Caschlatsch

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

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Monastery Views

Final Project location

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

SITE

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

12V

6V

6V

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

12V

6V

6V

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

12 boxes

6 boxes

6 boxes

432 boxes

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Ruina Caschlatsch

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Box grid = 70cm x 70cm

1.5m

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

Disentis/Muster

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Stairs

Main Interior Space

1.40m height room with possibility to sit around the space.

2.10m height room with bench on the side.

Zig-zag stair access to the top.

Around axis stair access to the top.

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1.40 m

0.70 m

8.40 m

4.20 m

Two modules on top for density

Main interior space

Staircase around the structure

Entrance point

350 boxes

82 crafted boxes

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Ruina Caschlatsch

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1.5m

Foundation points

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Computational Design : Clustering

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Negative Space (0) = 82 Voxels

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Positive Space (1) = 350 Voxels

Clustering: Voxel Grid

6V

6V

12V

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Search for optimal

Kernel (spatial matrix of voxels)

Search for fitting

Kernel (matrix boxes) solution

Clustering Workflow

Filter out kernels

(unreasonable for

structure/infill)

Pick a starting

point

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering

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Split into 4 slides

Mention constraints

Kernel

(spatial matrix of voxels) fitting

Clustering Workflow

Split into 4 slides

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering

Algorithm passes to nearest voxel with binary ID = 1

Each voxel inside

selected kernel

is assigned a Cluster ID

The Binary ID of voxles stored into cluster gets changed to 0

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Filter out kernels

(unreasonable for structure/infill)

Filter solutions to avoid

single voxel clusters

Searching in each segment

Filtered Hierarchy

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering

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Search for solution with more interlockings between layers

Filter the solution with less module horizontal/vertical alignments

​

Search for best

segment solution

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering

Filtered Hierarchy

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Rotate the segment

for interior space

Switch direction

for each segment

Slicing by even number

I

II

III

Step logic

increasing in direction

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering _ Grid Pre-Slicing

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering _ Grid Pre-Slicing I

Slicing by even number

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering _ Grid Pre-Slicing II

Step logic

increasing in direction

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Switch direction

for each couple of segments

Final clusters

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Clustering _ Grid Pre-Slicing III

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Voxel

Assembly Module

“Air” Module

(800 kg max. per flight)

Computational Design : Assembly modules _ Airmodules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Computational Design : Assembly modules _ Airmodules

Air - Module_02

1.27 T

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​

​

Air - Module_01

0.66 T

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​

​

Air - Module_03

0.85 T

​

​

Air -Module_04

0.95 T

​

​

Air - Module_03

0.77 T

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Air - Module_02

0.82 T

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Air - Module_04

0.55 T

​

​

Air -Module_05

0.55 T

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​

​

Air - Module_01

1.07 T

​

​

Air - Module_04

0.60 T

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​

Air - Module_03

0.59 T

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​

Air - Module_05

0.54 T

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​

Air - Module_06

0.68 T

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​

Air - Module_02

0.72 T

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​

Air - Module_01

0.67 T

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Assembly Modules

​

​

Air - Module

​

​

I

II

III

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Clustering: Clustering _ Grid Pre-Slicing _Comparison

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

I

II

III

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Carved = 372 Voxels

Clustering: Voxel Grid

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

6V

6V

12V

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Clustering: Final Cluster

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

6V

6V

12V

Carved = 75 Clusters

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1 x 1 x 3 = 12 Modules

Clustering: 1x1x3 Clusters

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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2 x 1 x 1 = 18 Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Clustering: 2x1x1 Clusters

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2 x 2 x 1 = 15 Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Clustering: 2x2x1 Clusters

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2 x 2 x 2 = 4 Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Clustering: 2x2x2 Clusters

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2 x 3 x 1 = 23 Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Clustering: 2x1x3 Clusters

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2 x 3 x 3 = 3 Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Clustering: 2x3x3 Clusters

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Clustering: Final Cluster

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Clustering: Final Infill

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Computational Design: Structure, Infill, Code Logic

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To Do:

​

  1. Overview Infill Logic
  2. Restrictions: avoid 3-element Joints + no collision
  3. Frame and Primary Verticals + Shift
  4. Structural Infill
  5. Globally informed + Foundation connection
  6. Extension of initial structure infill to face
  7. Face Diagonals (Projection)
  8. Truss (where possible)
  9. Primary Subdivision on faces (according to size and orientation) - show three examples

3x2x2, 2x2x2, 2x3x1

  • Angle limitation + Amount of points (due to angle limitation)
  • Code Logic / Structure and Benefits

Occupied / freepoints

Collision detection

Shifting of lines (offset)

Angle

Resolution

  • Gradual randomness towards top (angle)
  • Anti-Buckling Infill
  • Density Infill

Show smallest and largest module somewhere

Mention AxisVM (+ Screenshot?)

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Structure and Infill: Full Module

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

2 by 2 by 2 Module Infill

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Globally Informed Infill

Logic

Structure and Infill: Overview

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Locally

Informed Infill

Logic

Main Diagonal

Face Diagonals

Truss

Anti-Buckling Infill

Density Infill

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Structure and Infill: Restrictions and Rules

3-Element Joints Avoidance

Angle Limitation

Collision Avoidance

​

Min. and Max. Beam Length

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Compas Timber

CNC Machine Limitation

Assembly Sequencing

CNC Machine Limitation

Fabrication time

Wood volume

air_module weight

Fabrication Time

Total Timber Volume

Air_Module Weight

< 20 days

~ 10m3

< 800 kg

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Structure Code Logic: Overview

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Cluster Object:

ClusterID: 46

Centers: 2 (according to the size of cluster)

Cluster Original Units Count [X,Y,Z]: [3,1,2]

Offseted Cluster: To access centerlines

​

ClusterID: 46

. Foundations

LineBeam Object:

Geometry: Centerline

Cross Section: 60mm

Name: “vertical_0”

Unit Count: 2

Resolution: (unit_count * BASE_RESOLUTION)

​

​

​

Normal: normal

ID: 11

ClusterID : 46

Transformation : None

Points: Available points on LineBeam and their status

​

Free

Occupied

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Resolution of LineBeam

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

α max: 45°

d = 60 / sin(α)

α

60

d/2

d/2

60

d = 60

d/2

d/2

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

. Foundations

​

Producing the Main Structural Diagonals from centers to the foundations.

​

Side View

Top View

Using the projection of main structural diagonals on XY plane to produce Face Diagonal for each Assembly Module

​

. Center

​

Structural Infill: Main and Face Diagonals Production

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

ClusterID: 46

Main Diagonal Beams

​

Starting from 2 centers of the cluster

​

Producing the Main Structural Diagonals from centers to the foundations.

​

Face Diagonal Beams

Structural Infill: Main and Face Diagonals

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Structure and Infill: In Different Typologies

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

[ 1 x 2 x 1 ]

[ 3 x 1 x 1 ]

[ 2 x 2 x 1 ]

[ 1 x 1 x 3 ]

[ 1 x 3 x 2 ]

[ 2 x 2 x 2 ]

*Trusses are produced after Anti-Buckling Infill

ClusterID: 06

ClusterID: 67

ClusterID: 44

ClusterID: 32

ClusterID: 69

ClusterID: 34

[ 2 x 3 x 3 ]

[ 3 x 2 x 1 ]

ClusterID: 53

ClusterID: 72

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Different Strategies for Different Infill Elements

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

3. Second Anti-Buckling Beams

​

1. Verticals

​

2. First Anti-Buckling Beams

​

4. Density Infill

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1. Verticals

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

if Lower Module (in Z)

Bottom frame selection range = 3

Top frame selection range = 1�

fixed top selection depending on bottom frame point

​

if Higher Module (in Z)

Bottom frame selection range = 3

Top frame selection range = 3

random top and bottom selection

​

Increased Randomness

Free and in range

Occupied

Free BUT not in range

Free and in range

Occupied

Free BUT not in range

Verticals of Module 27

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2. Anti-Buckling: 1- For Frame or Verticals

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Anti-Buckling in Module 27

​

1 x 3 x 2

​

[ 3 Sections ]

​

Horizontal

2 x 2 x 2

​

[ 2 Sections ]

​

Cube

1 x 2 x 3

​

[ 3 Sections ]

​

Vertical

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3. Anti-Buckling: 2- For Structural Infill

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

  1. Finding “Free-Point” on start beam close to the center for �all long beams of module

​

  • Select one End-point from all “free-points” of module in range of max_length and remember to not repeat

​

  • Evaluating the test connection (max and min angle, max and min length and collision)

​

�Selected Start Point

On Selected Start Beam

�Selected End Point

If successful: LineBeam Anti-Buckling

If not successful: Choose another test end_point

�Selected Start Beam

max length 1.5m

Free and in range

Occupied

Free BUT not in range

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

  • Select a random start beam and remember not to select the same again
  • Select a random end-point from all “free-points” of module in range of max_length (and remember to not repeat)

​

�Selected Start Point

On Selected Start Beam

If successful result:

Make a LineBeam out of the test connection

​

If not successful: Choose another free_point in max_length

Free and in range

Occupied

If not successful: Choose another random start beam

4. Density Infill:

Selected Start Beam

�Selected End Point

Selected End Beam

  • Evaluating the test connection (max & min angle, max & min length and collision)

​

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Computational Design: Alignment and Adjustments

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θ

θ

30

30

x

30 - x

Shift_length

Shift_vector

x = tan(θ)*30

​

Shift_length = (30/cos(θ) + tan(θ)*30)-30

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Alignment and Adjustment: Bird’s mouth - Bird’s mouth to T-Butt - Bird’s mouth

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5mm pocket

Old center line

Shifted center line

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Alignment and Adjustment of Centerlines:

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Trimming off manually in fabrication process

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Trimming off manually in fabrication process

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Pre-calculations: Data extracted

  • Total weight
  • Weight by air-module
  • Volume of timber
  • Estimated time of production: 6 min per beam
  • Number of elements
  • Number of modules
  • Number of joints
  • Density parameter
  • Sorted information for comparison

​

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Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Statistics: Comparison

Total weight

Volume

Height

Number of modules

Number of elements

Number of air-modules

Max density elements

Estimated production time:

9h/day

12h/day

​

3.85 t

7.7 m3

8.4 m

75

2106

6

7

​

24 days

18 days

3.84 t

7.7 m3

8.4 m

80

2159

6

5

​

24 days

18 days

3.97 t

7.8 m3

8.4 m

80

2204

6

6

​

25 days

19 days

1

2

3

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Structural Analysis:

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Final Structural

Review (Specifying Cross Section Size, Glue and Screws)

Adjusted Line Model Rhino

Export to .STP

Export to JSON

COMPAS TIMBER

Joint Design and Fabrication

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Computational Design: Informed Modularization (Logistics)

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Overview: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

AM_06�

[ 1.34m3 ]

Airmodule_01: 670 kg

Airmodule_02: 725 kg

Airmodule_03: 595 kg

Airmodule_04: 600 kg

Airmodule_05: 545 kg

Airmodule_06: 680 kg�

Timber Density: 500 kg/m3

​

AM_05�

[ 1.45m3 ]

AM_04�

[ 1.19m3 ]

AM_03�

[ 1.20m3 ]

AM_02�

[ 1.09m3 ]

AM_01�

[ 1.36m3 ]

Helicopter Weight Limitation: 800 kg

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Proposed Subdivision:

Airmodule_01: 3 pieces

Airmodule_02: no subdivision

Airmodule_03: 3 pieces

Airmodule_04: 2 pieces

Airmodule_05: 2 pieces

Airmodule_06: 4 pieces

​

​

​

​

​

�

Truck Bed Dimension Types:

  • 7000mm (L) x 2400mm (W) x 2800mm (H)
  • 6200mm (L) x 2400mm (W) x 2800mm (H)

Land Transport: Transport Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Land Transport: Transport Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Land Transport: Transport Modules Assembly Sequence

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Airmodule_01: 3 pieces

Airmodule_02: no subdivision

Airmodule_03: 3 pieces

Airmodule_04: 2 pieces

Airmodule_05: 2 pieces

Airmodule_06: 4 pieces

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Air Transport: Air Modules + Air Jigs

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Air Transport: Air Modules + Air Jigs

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Lifting slings

60mm x 120mm secondary wood lifting beams

100mm x 300mm primary wood lifting frame

Rothoblass RAPTOR lifting hooks

Air Transport: Air Modules + Air Jigs

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

116 of 213

Module_01 :: V = 1.20 m3 /

W = 0.69 T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

117 of 213

Module_02 :: V = 0.98 m3 /

W = 0.545 T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

118 of 213

Scaffolding_01

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

119 of 213

Module_03 :: V = 1.13 m3 /

W = 0.610 T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

120 of 213

Module_04 :: V = 1.21 m3 /

W = 0.635 T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Scaffolding_01

Scaffolding_02

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Module_05 :: V = 1.45 m3 W = 0.765T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Module_06 :: V = 1.36 m3 /

W = 0.715 T

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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Scaffolding_01

Scaffolding_02

Scaffolding_03

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

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#

Module

Volume (M3)

Weight (T)

1

Module_01

1.20

0.69

2

Module_02

0.98

0.545

3

Module_03

1.13

0.610

4

Module_04

1.21

0.635

5

Module_05

1.45

0.765

6

Module_06

1.36

0.715

7

Flooring + bridge

0.34

0.17

Total

8.0

4.1

Assembly Logic: Air Modules

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

126 of 213

Fabrication: Tools

127 of 213

3DP Facade

​

​

  • Researching computational design and digital fabrication.

​

​

​

  • Managing huge quantities of diverse elements, dealing with complexity.

​

​

​

  • Based on our previous research conducted by the chair on the assembly of spatial timber structures, it is notably challenging and complex to assemble a structure using either only robotics or only human labor.

​

​

​

  • The solution involves augmented reality (AR); the phone will project the blueprint informing either the robot or the human involved into the assembly of the relationship that every wooden beam has with the whole structure in terms of position and joints

​

Design Process: Tools

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

DIVIDE INTO MULTIPLE SLIDEs

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Tools:: COMPAS_Timber

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

129 of 213

3DP Facade

Tools:: 5-axis CNC Holzer EPICON 7235

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

130 of 213

Tools:: Robot

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

131 of 213

Tools:: COMPAS_XR

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

132 of 213

Fabrication Workflow: COMPAS_Timber and BTLx

133 of 213

1 or 2 slides- Picture of RFL with all tools (robot, cnc)

134 of 213

Line Model�

ghpython/compas timber

Machine/Campus Ecosystem��NC Hops

Beam Module w/joints

​

Compas timber/ghpython

Easy Beam/Easy Hops

​

Easy Beam / python

Data Input

  • Centerlines
  • Normals
  • Module_id
  • line_id

Data Output

  • List CT_Beam

Data Input

  • CT_Beam
  • Joint rules
  • Feature (mill/drill) params

Data Output

  • BTLx file
  • CT_assembly -> building plan (XR)
  • Motion cap Data
  • Fabrication data
  • Blank length
  • Blank nesting in stock

​

Data Input

  • BTLx file
  • Machining params
  • Machine setup?

Data Output

  • .hop files

​

Data Input

  • .hop files

(Data) Output

  • Physical beam

​

Short intro compas timber:

  • Planning timber construction
  • - turning centerline into beams with specific joint and features

EXCEL SHEET TRACKING

Joint pictures IRL

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

135 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Fabrication Workflow: Overview

COMPAS_Timber

BTLx is a free standard that can be used for data exchange between different design software and between design software and machines.

BTLx

Line Model

136 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

EB

Fabrication Workflow: Overview

137 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

EB

Fabrication Workflow: Overview

138 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Centerline Model: Data Workflow

Data Input:

Attributes:

Data Output:

LineBeam

dict{}

Normal

cg_vector

Beam Dimensions

CT_Beam

compas_timber class()

Centerline

cg_line

​

ID

Module+Line ID

139 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

EB

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

140 of 213

EB

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

141 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Data Workflow

Data Input:

Parameters:

Data Output:

Joint Rules

Topo_L

Topo_T

CT_Beams

compas_timber class()

Feature Parameters

Drill Diameter

Mill Depth

Fabrication Data

.BTLx

CT_Assembly

compas_timber class()

Motion Capture Data

{.json}

Blank Nesting Data

.txt

142 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Topological Joint Rules

L-Connections

Topo_L

T-Connections

Topo_T

French Ridge Lap

Topo_L

Butt Joint

Topo_T

Step Joint

Topo_T

Birdsmouth Joint

Topo_T

143 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Joint Typologies

French Ridge Lap

Topo_L

Conditions:

  • Topo_L
  • Coplanarity
  • Orthogonality

Properties:

  • Self-aligning

144 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Joint Typologies

Step Joint

Topo_T

Conditions:

  • Topo_T
  • Coplanarity

Properties:

  • Load distribution of compression
  • Shear distribution

145 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Joint Typologies

Butt Joint

Topo_T

Conditions:

  • Topo_T
  • Not coplanar
  • Aligned faces

Properties:

  • Simple to machine
  • Easy to assemble

146 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Joint Typologies

Birdsmouth Joint

Topo_T

Conditions:

  • Not coplanar
  • T-Butt on other end

Properties:

  • Resisting lateral movements
  • Distributing vertical loads

147 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Features

Text Engraving

Additional Feature

Properties:

  • Identification during assembly and storage

Conditions:

  • Present on all elements

148 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

CT_Beam Model: Features

Hole Pre-Drilling

Additional Feature

Properties:

  • Preventing wood splits
  • Position and direction of screws
  • Reference for Motion captors

Conditions:

  • At each screw location

149 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

EB

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

150 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

EB

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

151 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: Data Workflow

Data Input:

Translation:

Data Output:

Fabrication Data

.BTLx

Fabrication Files

.hop

EasyHops

Custom Python script

​

EasyBeam

Machining software

​

152 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: BTLx Processes

DoubleCut

Birdsmouth

Step Joint

Joint/Feature

BTLx Process

French Ridge Lap

153 of 213

Joint/Feature

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: BTLx Processes

T-Butt

JackRafterCut

BTLx Process

154 of 213

Joint/Feature

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: BTLx Processes

T-Butt Pocket

Lap

BTLx Process

Step Joint Pocket

155 of 213

Joint/Feature

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: BTLx Processes

Hole

Drilling

BTLx Process

Marker

156 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Beam Features: BTLx Processes

Text

Text

Joint/Feature

​

BTLx Process

157 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

EB

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

158 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

EB

Fabrication Workflow: Overview

Centerline Model

Line Design

CT_Beam Model

Beams/Joints/Features

Beam Features

Processes

Fabrication

Machinings

159 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

BTLx Processes:

  • JackRafterCut
  • DoubleCut
  • Lap (StepJoint Pocket)

​

Blade Operations:

SawBlade D350

​

3.2 mm

351.29 mm

Fabrication: Tools

160 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

BTLx Processes:

  • Lap (TButt pocket)

​

Milling Operations:

Castor D61

​

61.092 mm

230.70 mm

Fabrication: Tools

161 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

BTLx Processes:

  • Text
  • Drilling (Pre-Drilling)

​

Engraving Operations:

Folding

​

41.5 mm

60°

228.938 mm

Fabrication: Tools

162 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

BTLx Processes:

  • Drilling

​

Drilling Operations

Drill 4mm

​

203.65 mm

4 mm

Fabrication: Tools

163 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Fabrication: Statistics

164 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Fabrication: Statistics

.BTLx

File

.hop Files

Blanks

DONE

Comments

ID

​

Real-Time Stats

165 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Fabrication: Statistics (2024/05/31- )

Date

Weekday

Production

% (Record Production)

2024-05-31

Friday

36

–

2024-06-01

Saturday

38

+3%

2024-06-02

Sunday

45

+18%

2024-06-03

Monday

52

+15%

2024-06-04

Tuesday

62

+19%

2024-06-05

Wednesday

71

+14%

2024-06-06

Thursday

77

+8%

2024-06-07

Friday

66

-14%

2024-06-08

Saturday

no production

–

2024-06-09

Sunday

50

-35%

2024-06-10

Monday

71

-8%

2024-06-11

Tuesday

108

+40%

2024-06-12

Wednesday

116

+7%

2024-06-13

Thursday

87

-25%

2024-06-14

Friday

57

-51%

Daily Average:: 66.8

Max daily production:: 116

​

166 of 213

Fabrication: Compas XR

Image will be replaced on Monday

167 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

XR App: Assembly & Stacking

168 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Communication & Data Workflow

169 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Communication & Data Workflow

170 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Communication & Data Workflow

171 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Communication & Data Workflow

172 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Communication & Data Workflow

173 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Data Format: JSON & OBJ

174 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Data Format: JSON & OBJ

175 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Data Format: JSON & OBJ

176 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

  • Change mode between�“Stack” and “Assemble”
  • Show beam orientation
  • Float beam
  • Scale assembled module
  • Switch Module
  • Info Panel of beam

177 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

178 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

179 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

180 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

181 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

182 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: The Stacking APP

183 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

184 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

185 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

186 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

187 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

188 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

189 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

190 of 213

  1. Two Parallel Assembly Setups

​

​

  • One Placement for Assembled Modules

​

  • 3-4 people team

​

​

​

​

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly: Assembly RFL SetUp

191 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly: Assembly RFL SetUp

Human_Robot_Collaboration

192 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly: Assembly RFL SetUp

Human_Robot_Collaboration

193 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly: Assembly RFL SetUp

194 of 213

​

​

  • Stacking Placement
  • Assembly Rail

​

​

​

​

​

​

​

  • Tools:

Glue Gun, ScrewDriver, Screws, Clamps, Phone/Tablet.

​

​

​

​

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly RFL SetUp: Assembly SetUp

195 of 213

​

​

  • Stacking Placement
  • Assembly Rail

​

​

​

​

​

​

​

  • Tools:

Glue Gun, ScrewDriver, Screws, Clamps, Phone/Tablet.

​

​

​

​

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly RFL SetUp: Assembly SetUp

196 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

User Interface: New development of COMPAS XR in this project

197 of 213

​

​

  • Stacking Placement
  • Assembly Rail

​

​

​

​

​

​

​

  • Tools:

Glue Gun, ScrewDriver, Screws, Clamps, Phone/Tablet.

​

​

​

​

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly RFL SetUp: Assembly SetUp

198 of 213

​

​

3-4 people team:

​

  • Stacking (stacking App)
  • Picking
  • Positioning(Compas XR)
  • Gluing
  • Screwing

​

​

​

​

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly RFL SetUp: 4 Teams (3-4 people)

1. -Stacking (Stacking APP) – Picking -Positioning (Compas XR)

2. -Gluing

3. -Screwing

199 of 213

​

  • QR Code Measure_In
  • Localization Frame
  • Design Frame

�

​

� ��

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Methodology: Digital Twin Positioning

200 of 213

​

  • Priority
    • 0:: Frames
    • etc.
  • Actor :: Human

​

�

​

� ��

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Defining Sequence: Assembly Human (90° Module_Flip)

201 of 213

​

  • Priority
    • 0:: Frames
    • 1:: Verticals
    • etc.
  • Actor
    • Human
    • Robot::
      • Pick Frame
      • Place Frame

​

�

​

� ��

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Defining Sequence: Assembly Human_Robot

202 of 213

�- Module_QR

​

  • Digital_twin adapts and changes position in real time

​

​

- Mocap Tracking:

​

  • Real Time Feedback System
  • Minimizes wrong beam placement� ��

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Future Explorations: Workflow Improvement

Video from Alex

203 of 213

Fabrication : Process Step by Step

204 of 213

1/6 : precut beams

205 of 213

2/6 : load a beam into CNC

206 of 213

3/6 : manipulate CNC and mill timber

207 of 213

4/6 : unload beam and stack it

208 of 213

5/6 : assemble module

209 of 213

6/6 : join modules together

210 of 213

Current State: Impressions

211 of 213

Wooden Beams Milled Till Date

936

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly

Assembly Modules Fabricated Till Date

24

Air Modules Assembled

01/06

Total Production Time To Date (Cut / Mill)

46.61%

Average Milling Time Per Beam

08 MIN

No. of Assembly Modules Per Day

03

212 of 213

213 of 213

Introduction

Global Design

Clustering

Structure & Infill

Fabrication

Impressions

Assembly