Manufacturing Diversity

Manufacturing Diversity

Recent Development of digital fabrication and computer aided manufacturing (CAM) in the building sector have a profound impact on Architecture as a material practice. The new advance process of using steel, timber and membrane fabrication and the whole construction process need precise manufacturing and investigation. Some world leading manufacturing companies for example- CoverTex, Finnforest Merk, Octatube Space Structure, Seel and Sky span.

Architecture as a material practice as well as it is designing our life- changed rapidly last few decades through the increasing number of geometrically complex design using totally a different way of manufacturing and installation process. The material become much more diverse and uniq than in days of mass production and standardization of building element/ building system. The most important innovation behind this new system is the computer aided manufacturing which using Computer Aided Design(CAD) data as a input and mass precise physical units- are too complex to make manual process. So this Critical evolution shifts the whole paradigm from mass production to production of different building element ans system. Initially the manual process called Control Numerical (CN) was used for metal working application developed by US army.

This divers range and emergent digital manufacturing process by the world leading companies
drive us to draw the outline of advanced manufacturing and fabrication for the future tectonic
possibilities in architecture design. For example - Octatube space structure they are using computer aided composite sandwich manufacturing and Explosive panel forming technology.
For building example- such technics has used in Municipal Florida Pavilion in Hoofddrop. Explosive forming technique is used to create 3D metallic panels of different size ,shapes,
curvature and depth. Actually in this process the sheet metals are forced to melt into dies through the detonation of explosive under water and the vacuum creates the cavity and shape uniformly.

This Digitally driven membrane engineering and Fabrication, CNC penalization, Integrated steel
and glass facade construction , robotic timber manufacture process all these are the existing and
emerging manufacture technics of digital production still has a huge possibilities of undiscovered
potential of new innumerable new means.

Actually this whole article deals with in depth research into the current possibilities and future
perspectives of fully integrated computer aided design and manufacturing- presenting with some
world leading new companies and the process of Installation , construction and real challenges.

Source: Achime Menges’s article, 2006, Manufacturing diversity AD 76/2,Page 180)


Fig: Explosive formed plate access hole in Fermilab vacuum vessel.


Explosive forming

The technique of shaping metal by means of explosions has been around since the late nineteenth century. It was first used for engraving and punching iron sheets and entailed applying explosives directly to the iron. The thickness of the sheet determined the depth of the relief. In the early twentieth century, explosive forming was used chiefly in the weapons industry. After the Second World War, the technique was used in the space industry for producing complex, double curved components like the top of the Saturn V rocket, but also for fuel filters, corrugated panels and asymmetrical exhaust elements for the very first jet engine planes.

Nowadays explosive forming, also known as High Energy Rate Forming (HERF), is used not only in the aerospace industry but also in the energy and construction sectors. As well as double curve panels, it is especially suitable for embossing flat sheets of metal. Nearly all types of metal – aluminium, steel, stainless steel, nickel and titanium – can be formed using explosive forming techniques.

There are two different methods – direct (contact) and indirect (standoff). In the direct method the explosive charge is applied directly to the sheet of metal. The force of the explosion presses the sheet into a mould and so shapes it. This method, which entails a lot of force and a high risk of production defects, is no longer used.

In the indirect method the explosive charge is transmitted via a liquid medium. The workpiece is placed on a die and a vacuum is created in the cavity between metal and die. The whole is then hoisted into a bath of liquid. The explosive charge is placed above the sheet of metal in the liquid and detonated, forcing the metal into the die at very high speed. Standoff explosive forming usually takes place in a tank of water, but other liquids are also used. The most commonly used explosives are TNT and RDX (Cyclotrimethylenetrinitramine, an explosive material often used in military weapons today but which was still being prescribed as a medicine in 1890).

Explosive forming uses a single die half which must of course be able to withstand the force of the explosion but otherwise the choice of material depends chiefly on the cost and processing involved. Steel and aluminium are favourites but there are also instances of MDF and concrete being used.

Compared with other metal forming techniques, explosive forming has several advantages. It allows large objects up to ten metres in length to be formed in a single operation, and it can deform sheets of stainless steel up to six centimetres thick. It requires less post-formation tooling which puts less strain on the metal. It can also cope with anodised or coated metal sheets which leads to lower overall costs than other techniques such as vacuum forming and pressing. Explosive forming is especially suited to making prototypes or small production runs, although larger runs can also be produced by deforming several sheets simultaneously.

Source: Http://www.materia.nl/583.0.html?&tx_ttnews[tt_news]

Computer-aided manufacturing (CAM)

Computer-aided manufacturing (CAM) is the use of computer-based software tools that assist engineers and machinists in manufacturing or prototyping product components. CAM is a programming tool that makes it possible to manufacture physical models using computer-aided design (CAD) programs. CAM creates real life versions of components designed within a software package. CAM was first used in 1971 for car body design and tooling.

Recent developments of digital fabrication and computer-aided manufacturing (CAM) in building sector have a profound impact on architecture as a material practice. In last 5 decades- the design and construction methods changed radically beyond regular forms.
Source: Http://en.wikipedia.org/wiki/Integrated_Computer-Aided_Manufacturing



Fig: Advanced Processed applied in steel, Timber and membrane febrication and construction

CAM- Computer aided manufacturing

Herzog and De Meuron's Allianz Arena


Fig: CAM Panel assembling
1st Image Courtsy: www.admin.technion.ac.il
2nd Image Curtsy: www.sponsoring.allianz.com/nopi_downloads/photos/


Image Curtsy: www.sponsoring.allianz.com/nopi_downloads/photos/



Fig : Construction of allianz arena’, munich (germany), 2004 (finished 2005)
Architect: herzog and de meuron
Image courtesy: www.designboom.com/contemporary/stadium.html


Construction Phases



Image Curtsy: www.sponsoring.allianz.com/nopi_downloads/photos/



Munich's world cup stadium Allianz Arena is the most modern football stadium in Europe. It has been inaugurated in 2005, one year before the FIFA world cup took place in Germany.

Allianz Arena Munich This futuristic looking stadium is the home of two German Soccer League teams: the famous FC Bayern Munich and the TSV 1860, also called Löwen (engl.: Lions).

The facade consists of inflated panels, that can be lighted from inside and shine in three different colors: white if there's no match, red for FC Bayern Munich and blue for the Lions TSV 1860. Colors can be mixed for special events and make a great spectacle at night.

Source: www.inside-munich.com/allianz-arena-munich.html

Some World Leading Manufacturing Companies

CoverTEX



1st Image: Exibition Stand "Bionics" for Siemens, Dresden, Germany
2nd Image: BMW Clean Energy, EXPO in Hanover, Germany
During the international EXPO 2000, BMW exhibited a model of the
technical progress of hydrogen technology.

Source: http://www.covertex.de

Finnforest Merk



Wood is the only renewable construction material. It is aesthetic, elegant and has endless structural possibilities. Those features, coupled with Finnforest's extensive experience, unite to form the most impressive constructions made of wood.
When building with wood or any other material, a diverse product range and comprehensive know-how from planning to realisation are needed. Finnforest has products for simple buildings as well as the most complex public projects.

Source: http://www.finnforest.co.uk

Expo Dach- by Finnforest



Location: Hannover, Germany
Building year: 2000
Architect: Herzog + Partner
Structural designer:
Constructor:Customer:
Deutsche Messe AG.
Source: http://www.finnforest.co.uk

Woodcoaster- by Finnforest



Location: New Jersey, USa
Building year: 2005
Architect: Structural designer: Constructor: Intamin Transportation Ltd.
Customer: Finnforest materials used: Kerto tracks

Engineer: Stengel GmbH, Munich
Source: http://www.finnforest.co.uk

Skyspan

The Skyspan Group offers the benefits of the largest membrane manufacturing and fabrication capabilities in the world plus the technical expertise arising from our long history of successful completion of prestige projects around the world.

Waldstadion Frankfurt, Germany



Size : 9,500 sqm PVC-PES retractable
22,500 sqm PTFE-Glass

Material : PVC-Polyester fabric
PTFE-Fibreglass fabric

Client : Stadion GmbH Frankfurt, Germany Contractor
Max Bögl GmbH & Co. KG, Neumarkt, Germany

Architects : gmp, Berlin, Germany
gmp, Frankfurt, Germany

Engineer: Schlaich Bergermann & Partner, Stuttgart, Germany

Membrane Consultant: Kurt Koch, Kastanienbaum, Switzerland

Membrane Engineering: Skyspan (Europe) GmbH, Rimsting, Germany
IF Ingenieurgemeinschaft Flaechentragwerke,
Reichenau, Germany

Cables: Pfeifer Seil & Hebetechnik GmbH,
Memmingen, Germany

Source: http://www.skyspan-umbrellas.com.au/

Architectural Membranes Database:

We welcome you to the exciting world of Architectural Membrane Architecture - the building material for the new millennium. We invite you to let your creative talents run free.

Architectural membranes - these fascinating building materials appeal to the everyone’s visual and aesthetic senses - building upon the purest natural forms in design and construction.

Seeming to float weightlessly, these versatile architectural materials can be used to create vast spans, light-flooded places, unique lighting effects, yet they are weather resistant, immensely strong, durable, technically advanced and most of all, cost effective.

The endless creative possibilities of membranes give architects and designers a wonderful opportunity to communicate their vision. The unique possibility to make free flowing shapes; to integrate with other materials; to contrast transparency and opacity - to challenge the senses.

Introducing the materials

PTFE-Fibreglass fabric
Top range fabric, for permanent structures only, high reflectance, maintenance free, self-cleaning, highest fire resistance, limited colour possibilities, light transmission up to 20 %, life expectancy over 25 years

PVC-Polyester fabric
Economic product line for temporary, permanent and retractable structures, easy-to-clean surface properties, self-extinguishing, various colours, light transmission up to 15%, life expectancy 15 to 20 years

ETFE membrane
High grade films for air-supported roof or facade modules, double or multi-layer system for insulation, self-cleaning, lowest fire load, self-extinguishing, hail-resistant, clear or white, limited colour possibilities, light transmission up to 90 %, life expectancy over 20 years

Translucent PVC-membrane
Translucent membrane for light ceilings, easy-to-clean surface properties, self-extinguishing, light transmission 70 %, life expectancy 10 to 15 years

Uncoated fabric
Highest class woven membrane, for permanent and especially retractable shading structures, optimum folding capability, non-waterproof, non-flammable, extreme UV-resistant, high reflectance, limited colour possibilities, light transmission up to 35 %, life expectancy of over 20 years

Mesh fabric
Open weave nets made of compounds, materials or stainless steel for windbreaks, shading, acoustic liners, interior design colours, flame rate and life expectancy depending on material

Source: http://www.skyspan-umbrellas.com.