Okan Basnak

Abstract

This research investigated building components that can be produced and transported in a flat state and transformed to a spatial state without scaffolding on-site. Curved folding was employed to allow for a shape change between flat and spatial bending active structures. Bending generally allows for expressive curvature with simple flat production as well as easy customization. Limitations presented by laborious forming and upscaling of individually bent plates were overcome by large-scale curved folding. The present research builds upon the context but adds a design framework for volumetric curved folded components, a bistable behavior, and comprehensive detailing regarding upscaling and increased structural capacity. The mechanism was studied on a kinematic level, considering geometrical rules of curved folding and the design space. It was also studied on a kinetic level under the consideration of material properties specific to plywood. As a proof of concept, a 1:1 scale demonstrator was built. Finite element modeling software was used to optimize the shape. The demonstrator was fabricated flat, folded up, and locked in its stable configuration by the bistability and bases. It supported twelve people with a self-weight of approximately 300kg.

Abstract

Fiber Reinforced Polymers (FRPs) are increasingly popular building materials, mainly because of their high strength to weight ratio. Despite these beneficial properties, these composites are often fabricated in standardized mass production. This research aims to eliminate costly molds in order to simplify the fabrication and allow for a higher degree of customization. Complex three-dimensional shapes were instead achieved by a flat reinforcement, which was resin infused and curved folded into a spatial object before hardening. Structural stability was gained through geometries with closed cross-sections. To enable this, the resource-saving additive fabrication technique of tailored fiber placement (TFP) was chosen. This method allowed for precise fibers’ deposition, making a programmed anisotropic behavior of the material possible. Principles regarding the fiber placement were transferred from a biological role-model. Five functional stools were produced as demonstrators to prove the functionality and advantages of the explained system. Partially bio-based materials were applied to fabricate the stool models of natural fiber-reinforced polymer composites (NFRP). A parametric design tool for the global design and fiber layout generation was developed. As a result, varieties of customized components can be produced without increasing the design and manufacturing effort