The faceted facade panel type aggregates a single geometry into an opaque wall condition that transitions into thin, horizontal louvers.

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1 acma composites challenge: faceted facade panels david varner + david graham

2 The faceted facade panel type aggregates a single geometry into an opaque wall condition that transitions into thin, horizontal louvers. Forming a rain screen and solar shading device, the panel composition may be applied to the exterior of a building or serve as interior partitions. Fabricated from the cheap and energy efficient method of cnc wire cutting, the molds that form the composite panels are lightweight and re-usable allowing for repeatable iterations.

3 x/3 x/3 x/3 Early tiling studies were conducted to analyze geometries between classical and modern aggregations, as well as differentiation of panel material type. The following examples represent repeatable tiling techniques that minimize tile uniqueness and cost of fabrication. 60 x 3 6 x/3 x/3 x/3 x Eye Film Institute Delugan Meissl Amsterdam, Netherlands aluminum panel direction rotates 60 CW tesselation tiling diagrams 3

4 Ono Wall Tile Dex Industries Atlanta, GA high performance concrete basketweave brick cairo pattern overlay Irregular Tesselations Convex Uniform Tiling cairo pentagonal tiling archimedean lattice rhombille tiling archimedean lattice Yu-un Guesthouse Tadao Ando, Olafur Eliasson Tokyo, Japan platinum-glazed ceramic tiles 4

5 The prime tile type is produced from a rectangular prism subtracted by a faceted surface. Tiling permutations follow simple translation, rotation, and reflection transformations. panel geometry development 5

6 The prime tile is reflected to create a new tile unit that is repeated along a row. Each subsequent row shifts by one tile to create a multi-faceted aesthetic. The solid tile is imaged as a wall panel while the faceted surface is extracted to form a thin panel to be used a horizontal louver. A transition tile is created to link the solid tile to the surface tile. panel geometry development 6

7 An early prototype expressing the shift from solid tiles to surface tiles, opaqueness to transparency. wall to louver condition 7

8 In order to produce formwork for the fiberglass application, the cnc hot wire cutter was used with eps foam as the medium. composite panel foam formwork female mold exploded mold wire cutting geometry production tool 8

9 The cnc hot wire sends an electric current across a titanium wire in order for it to slice through expanded polystyrene (eps) foam. The machine takes a.dxf input and addresses two colored profiles as the front and back geometries that pair with the front and back trolleys. The trolleys of the machine move independently across an x and y axis, allowing the wire to cut complex shapes in a small amount of time with a small amount of power. front geometry back geometry.dxf geometry exported to CNC wire cutter 00:10 00:20 00:30 00:40 00:50 01:00 cnc hot wire 9

10 combined.dxf front profile back profile The front trolley follows the front profile while the back trolley follows the back profile. Both trolleys are fully syncronized on the x and y axis at the start point and end point. From the start point, the trolleys lead-into the foam and begin to cut its primary geometry. The trolleys then traverse in order to re-sync before making the boundary cut of the shape. At the end of the cut, both trolleys lead-out to a common end point. 1 2 start point lead-in 3 facet cut 4 traverse 5 boundary cut 6 lead-out to end point wire cutter sequence 10

11 The first foam cut prototypes focused on an earlier hexagonal form. These tests used aluminum foil and wood glue as a mold release. foam cut assembly aluminum foil attached with spray adhesive one layer of fiberglass applied two coats of wood glue to protect foam from resin component of fiberglass application, no foil used, two layers of mold release used one layer of fiberglass applied fiberglass attached to glued surface two coats of wood glue became thick enough to peel off fiberglass, although tidious early prototypes 11

12 The second batch of prototypes focused on different surface finishes for the fiberglass. spray adhesive and saran warp wood glue and acetate wood glue and aluminum foil with one coat of mold release compound wood glue and aluminum foil with two coats of mold release compound easy to de-mold, fast application clean and smooth surface finish, easy to de-mold relatively smooth surface easy to de-mold, relatively smooth surface bumpy surface, saran wrap rips off difficult to cut, shape, and glue acetate have to let glue dry before applying foil, foil easily rips up time consuming to apply multiple coats. early prototypes 12

13 The third batch focused on sandwich panels, with a piece of balsa wood between two layers of fiberglass. The structural stability of these products were great while the balsa wood provided a fine aesthetic. bare foam with spray fixed aluminum foil, two layers of mold release (becomes standard) balsa wood cut to match facets (one with laser cut perforations and one without), two layers of fiberglass per unit surface quality and structural integrity were outstanding, no clear difference in strength between the two tests early prototypes 13

14 The assembly of this prototype required seven unique foam shapes, all derived from the prime tile type. desired geometry derived from tile unit female foam mold composite panel fiberglass balsa wood fiberglass foam mold with aluminum foil and mold release early prototypes 14

15 The fourth prototype became the predecessor for the final design solution. It features the prime tile type morphing into a horizontal louver of the same geometry. individually cut foam segments glued together aluminum foil spray fixed to mold, two coats of mold release perforated balsa wood cut in placed in between layers of fiberglass final product has exceptional surface quality and strength early prototypes 15

16 The design solution was derived from this axonometric wall assembly composing of two opaque walls flanking a horizontal louvered section that overlooks a glass facade. building integrated system 17

17 Opaque walls hold their own structure while the louvered sections are clipped onto the structural mullions of the glazing system. building integrated system 18

18 prototype parts a and b foam mold 19

19 prototype part c foam mold 20

20 The final design takes two shifted opaque panel walls and unites them with thin horizontal louvers. The walls provide a rainscreen for the interior space and may embed foam insulation. The louvered portion covers a window assembly and is directly attached to the mullions via metal clips. final design solution 16

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