4.212 Design Fabrication Design, Computation and Computer Controlled Devices. Prof. Larry Sass Department of Architecture and Planning

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1 4.212 Design Fabrication Design, Computation and Computer Controlled Devices Prof. Larry Sass Department of Architecture and Planning

2 Design Fabrication is an introductory course in the field of advanced computing, prototyping and building fabrication. The class is focused on the relationship between design, various forms of computer modeling both explicite and generative and the physical representation of information using rapid prototyping devices. The office of Gehry Partners, and Norman Foster have mastered computational techniques using CAD CAM technologies to construct buildings such as of the Guggenheim Museum in Bilbao, and the Swiss Re building in London. These offices use various methods of computer modeling to run computer controled devices (CNC Machines) at the end of the design process. In contrast this course will explore tools and techniques taken from these offices and current research projects using rapid prototyping and apply them to the new design office. The work will explore the idea of the design office built of computers and small rapid prototyping devices that simulate the CAD CAM process. Questions in the course will be focused how will these methods change the language of design and the current design process. This course is taught in five phases starting with simple rapid prototyping using solid modeling software, and end with digitally mockuped building components fabricated from CAD files using CAD CAM devices in collaboration with Parametric modeling software. The course meets once a week with a lecture and a hands on session to following.

3 THE USE OF RAPID PROTOTYPING DEVICES IN DESIGN 1. Historical Background 2. Theoretical Framework 3. The Course

4 PALLADIO WORKSHOP

5 Past Courses PALLADIO WORKSHOP Course focused on digital representation of Palladio s unbuilt villas 1999 Palladio Workshop, Students studied the façade of San Giorgio Maggiore. Students spent a lot of type studying Palladio s construction details.

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7 Past Courses Study of Construction Details Detail of a missing dentil from the façade of San Giorgio. It was said by the masons working on the reconstruction that the stone used to build the dentil was turned with its grains facing the wrong direction

8 Past Courses Study of Palladio s original drawings Students spend a day in the Palladian archives reviewing Palladio s original drawings

9 Past Courses COURSE PROJECT Complete the design for the unfinished Villa Porto in Molina Only the eight columns of the Villa Porto remain. Once the design of the floor plan is found the remaining parts of the villa can be built from the construction rules.

10 DIGITAL MOCKUPS

11 Past Courses DIGITAL MOCKUPS 2002 The course was a studying in digital fabrication and materials. Dennis Shelden of Gehry Associates and Mark Burry of RMIT with MIT created a class between two schools, studying one project. Students conversing on line with Dennis Shelden who is on the television monitor.

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13 Past Courses CLASS TRIPS During spring break we went to the experience Music Project and a quick visit to Frank gehry s office The experience Music Project in Seattle

14 Past Courses FIELD STUDIES Full scale detail study of the Stata Center Frank Gehry reviewing a mockup

15 Past Courses GENERATIVE FABRICATION GENERATIVE DESIGN WORKSHOP The course concentrated on the study of lighting design using generative techniques for design and rapid prototyping as a means of reflection Student Presenting a model to Hugh Whitehead, Judit Kimpian and Francis Aishe at Foster s office in London

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19 Past Courses Use of CAD to generate building Details and Connections 2003 Class visit to the Swiss Re tower

20 LECTURES Session A Design and Fabricating in Solids Session B Curves and Complex Design Fabrication Session C Design with CAD CAM Fabrication

21 Session A Design and Fabricating in Solids September 8 September 29 Lecture 1 Lecture 2 September 8 INTRODUCTION TO DESIGN FABRICATION September 15 NUMERICALLY CONTROLLED September 22 STUDENT HOLIDAY Lecture 3 September 29 ASSEMBLIES

22 Session B Curves and Complex Design Fabrication October 6 October 27 Lecture 4 October 6 DESIGNING WITH CURVED SURFACES & COMPLEX GEOMETRY October 13 STUDENT HOLIDAY (COLUMBUS DAY) Lecture 5 October 20 SCALING Lecture 6 October 27 TOLERANCE

23 Session C Design with CAD CAM Fabrication November 3 December 8 Lecture 7 November 3 PARAMETRIC DESIGN AND RAPID PROTOTYPING November10 STUDENT HOLIDAY Lecture 8 Lecture 9 November 17 DETAIL DESIGN AND CAD CAM FABRICATION November 24 CONSTRUCTION METHODS FOR PAPERLESS ENVIROMENTS December 8 STUDENT PRESENTATIONS

24 ASSIGNMENTS Study of Space (1) Assignment 1a Assignment 1b Assignment 1c Laser Cutting 3D Printing ASSEMBLIES I Building of Walls(2) Assignment2a Assignment 2b Assignment 2c Paper Cutting and Curves Fuse Deposition Modeling ASSEMBLIES II Design of Details (3) Assignment3a Assignment3b Assignment3c Modella & CNC Miling Waterjet Cutting ASSEMBLIES III FINAL ASSIGNMENT (4)

25 GRADING (Full participation in all aspects of the course) Attendance and participation in class 20% Assignment #1-20% Assignment #2-20% Assignment #3-20% Assignment #4-20% COURSE POLICIES 1) Students are expected to complete all 9 assignments to full completion for a grade 2) This semester will not support teams of students working on one assignment. 3) Incompletes are not accepted. COURSE FEE $100 Covers 9 Cubic Inches of Plaster for ZCORP MACHINE 6 Cubic Inches of ABS Plastic 4 Cubic Inches of High Density Foam Due in Class Sept 15 *Does not cover the cost of Final Assignment or Metals

26 COURSE STRUCTURE Course Website: Office Hours: Larry Sass Wednesday Friday 1PM 5PM (By Appointment) Carlos Barrios: Wednesday 9AM -12PM Materials Course Text: Inside Rhinoceros Cheng, Ron K. C. Onword Press Weekly Readings Course Organization Lectures 9 Exercises 3 Assignments 1 Final Project Lectures and Assignments are posted on Stellar 9AM) Recitations Monday 11AM 12:00PM

27 COURSE STRUCTURE Computer Programs: Windows Based Software 1) Autocad or Your Favorite Program 2) Rhino 3) Catia No Course Limit Fabrication Times Will Be In Groups Associated Groups Design Fabrication Group Center for Bits and Atoms

28 WHAT WILL YOU LEARN Rapid Prototyping and CAD CAM Design and Construction of Curved Surfaces Design and Construction of Building Details Exposure to Upcoming Technologies