From the ground up

Abstract

When designing for structural performance, the geometry of the load-bearing elements is crucial for achieving the required stability. This is even more important in structural forms, such as shells and arches that are predominantly designed by their structural requirements. However, the typical design process starts with the design by the architect, and the subsequent analysis and development by the structural engineer, resulting in inefficiencies, not only in the process but also in the sub-optimal result, as the more developed a project, is, the least effective and more costly it is to optimize. Therefore, this report outlines the development of an automated pipeline that integrates the whole lifecycle of a structure, from conception to end-of-life. The focus is on developing an integrated workflow for designing and fabricating a structurally optimized shell using computational methods for form-finding, structural and lifecycle analysis, as well as fabrication, with the end goal of facilitating an automated additive manufacturing production. The structure should be able to withstand applied wind and snow loads using construction materials that are strong in compression, such as earth as a load-bearing material. The design should also be adaptable, within the limits of the material strength or the spatial constraints of the system. In the beginning, the topic is introduced and the research framework is defined. The relevant laboratory and numerical tests are mentioned. Next, literature research is conducted in the relevant fields. More specifically, the research are avenues are divided into form-finding shell structures utilizing computational tools, in earth as a construction material and in additive manufacturing in construction, as well as context. Then, a research by design method is adopted in two directions; a physical set-up and workflow for robotic additive manufacturing with earth is developed, as well as an optimal mixture that makes the most of the capabilities of the developed set-up. Next, a computational form-finding and digital fabrication process that are informed by the developed material and physical setup are defined. The generated form will be evaluated with finite element analysis (FEA) software. The algorithm integrates stress line additive manufacturing principles to direct load paths. The resulting forms are compared with corresponding non form-found and form-found shells in terms of material reduction, as well as with standard construction for environmental impact. This project contributes towards the establishments of an optimized scientific workflow bridging the gaps between design and manufacturing, as well as the development of standards for assessing the safety and environmental advantage of 3D printed structures.