Aggregated Lamination

One of wood’s defining characteristics is its anisotropy resulting from its fibrous structure. Many
manufacturing methods and engineering processes in wood lamination have tried to overcome this
inherent natural quality, attempting to create a more homogeneous, isotropic composite. This
research projects aims at investigating whether there can exist an in-between state of operation that
takes advantage of both anisotropic natural qualities as well as isotropic lamination techniques,
where a hierarchical organization of localized, heterogenous laminated constructs coupled with the
global arrangement precalculated assembly system can create an engineered three-dimensional
matrix of lamination whose reaction is as predictable as a manufactured composite but whose
performance is as particular as that of natural wood.
By introducing specific weaknesses into a 2-ply maple laminate, one is able to control its
deformation when force is applied. When two different laminates with specific weaknesses are
bonded together through clamp molding, a “notch” with precise local geometry is created. This
resultant notch has specific angular directionality that is related to its two 2-ply maple laminate
components. Therefore, the global geometry is informed by the accumulation of local angles.
The final prototype takes advantage of the grain direction, which runs parallel to gravitational forces,
along with an even distribution of notches. Arranging the notches along curved paths prevents global
buckling by distributing the weaknesses. The related fabrication process utilizes both the vacuum
and clamp molding. The molds are constructed so that variation between the notches is minimized.
This precision allowed to accurately predict the resultant angles and to properly size and locate each
plate.
The developed system incorporates a number of morphological features that allow for assembly and
stiffness: [i] The channel that runs along the flat area of each laminate stiffens this section so that the
geometric control of each unit occurs only in the notch. [ii] The “feet,” the section of each unit that
meets the ground, is molded with additional curvature to increase the stiffness of this area. In
addition, varying the depth and length of the feet adds structural depth to this area. [iii] The plates
made from 1/8” plywood prevents local sheering, distributes the compressive forces along the edge
of each notch, and locks each notch into its intended location. [iv] The threaded rod runs through
seven laminated units and allows pre-stressing the entire structure.
Performative Wood Studio (Achim Menges)
Yarinda Bunnag, Aaron Goldstein, Marcin Mejsak, Paul Merrill
Harvard University Graduate School of Design, 2010

Kerf-Based Complex Wood Systems

This research projected investigated complex wood systems constructed from steamed, free formed
wooded slats and formed through strategic accumulative local weakening and disruption of fiber
continuity by kerfing. Thus the project aimed to develop an integrated computational design tool and
robotic manufacturing process that allows programming the bending and twisting behavior of
tensioned wood elements through specific kerf patterns.
Because of wood’s anisotropic characteristics, material perpendicular to the main grain direction can
be removed without overly compromising the overall structural capacity. In boat construction,
furniture making and other fields, regular kerfing is a well known technique for fabricating wooden
parts bent in one direction. This project explored how the computer controlled variation of kerf depth,
length, frequency and orientation allowed for achieving more elaborate bending and warping figures.
Understood as a system of cumulative kerfs, the macro-scale manipulation of the wooden slats prior
to steaming modifies their bending behavior. Constant kerf depth results in stress concentration at
the end of the kerfed length, leading to the isolated activation of these regions and consequently
produces kinks at these points. However, varying kerf depth gradually in relation to the stress
distribution allows for calibrating the bending stiffness with material removal. For example, if the
depth variation of parallel kerfs follows a sine curve, the resultant figure displays gradual curvature
change avoiding stress concentrations or kinks. Robotic sawing provides the required variability and
precision to instrumentalize kerfing in this way.
A custom-designed rotary saw tool for a 6-axis robot was constructed and enabled the testing of
related process parameters as for example, saw blade revolution, feed rate, climb cutting and
conventional cutting, etc. in relation to geometric kerf parameters including kerf depth, length,
frequency and orientation. The behavioral characteristics of the resultant test pieces together with
the fabrication parameters were integrated in a computational design tool and tested through the
construction of a larger scale prototype.
As initial tests had shown that specific kerf patterns allow for achieving a system-geometry with
negative Gaussian geometry once an assembly of multiple kerfed elements is pre-stressed, the
prototype was developed as an irregular hyperboloid global system consisting of more than 140
elements with unique local kerf patterns. In order to “program” the physical forming behavior of each
element, the computational design tool generates the individual kerf patterns, provides the relevant
geometric data and outputs this directly in robot control code. This enables the direct fabrication of
the individual kerfed pieces, which were subsequently steamed, pre-stressed, assembled into larger
components and finally erected as the 5 meter tall hyperboloid prototype.
Performative Wood Studio (Achim Menges)
Brad Crane, Andrew McGee, Marshall Prado, Yang Zhao
Harvard University Graduate School of Design, 2010

Discontinuous Strut Lattices

This project explores the limits of a material system consisting of uniform elements only. In doing so,
it uses basic semi-finished products that exist in abundance in any DIY store: identical timber struts
and cable-ties. The starting-point of the research was the recognition that, with all material elements
being the same and only one joint type available, the way to create an irregular morphology from
uniform elements is by altering the orientation of the sticks at each connection point within the
system. The crucial parameters for connection were identified as the location of the connection point
along the length of a strut, and the way struts were layered within a sub-assembly. Once logic of
various sub-assembly had been established the possibilities embedded in the critical two parameters
became apparent – altering the location of the struts either above or below each other and changing
the distance between the connection points results in changing angles of the initially perpendicularly
oriented sticks. This behaviour was carefully mapped and analysed in order to establish the range of
curvature that could be induced between sub-assemblies. It became the key for the proliferation of
the eight-strut sub-assembly into a larger and more varied system.
Further tests corroborated the relation between specific, digitally defined connection protocols, the anticipated system
geometry and the resulting, physically modelled assemblies. Through these tests six different assembly types were
identified, each with a specific adjustment scope defined by parametric variables. Possible configurations included
acutely curved, convex and concave-to-planar lattice articulations. Furthermore, the critical parameters for a full-scale
prototype could now be precisely described. A large prototype was built or, rather, a large prototypical assembly was
taken through different stages of element addition and subtraction and different levels of connectivity between lattice
layers. The alteration of connectivity showed that difference in curvature between connected layers can substantially
increase the load-bearing capacity of the assembly by increasing stiffness, which makes it possible to change the
orientation of the assembly relative to the axis of gravity without jeopardising its structural capacity.
The resultant, self-supporting, multi-layered and intricately curved material system assembled from
thousands of identical timber sticks and cable-ties begins to reveal the geometric complexity and
spatial opportunities afforded by this research. If design intelligence were invested in the bottom-up
process driven by material experiments and digital modelling, mapping and analysis, a complex
morphology could be developed, controlled and articulated by just two different, yet uniform, system
constituents.
GPA 01 Studio (Michael Hensel, Achim Menges)
Jeremy Richy and Nathan Smith, Rice University, Houston, 2004

Continuous Laminae
This research commenced from an interest in the anisotropy of wood, with its specific fiber-
directionality and related response-range to environmental stimuli tested against the specific
requirements of the context, a coastal sand dune conservation area in which the shifting of sand
dunes is critical. Initially the basic elements were finite length strips made from layers of laminated
veneer; rotating layers against one another allowed an investigation of different fiber-layouts. Shifting
the layers of veneer made possible a continuous lamination process, so as to produce a large
assembly without construction gaps. A correlated manufacturing strategy was developed,
incorporating the possibility of rotating selected sub-locations along their long axis. Replacing the
moulds with a nodal support system allowed the laminated components to be clamped at the end
points and so made self-organising, that is, able to find their form within the given constraints during
the fabrication process.
Achieving a laminar flow by maintaining curvature continuity between the individual elements results
in a continuous multiple load-path system that, together with the anisotropic characteristics of timber,
this helps to maintain the flexibility and integrity of the overall assembly. Furthermore, while the
overall assembly consists of finite lengths of veneer strip, the continuous laminae arrangement does
not yield a division into elements. The overall assembly becomes a single element, in which each
local dimensional change produced by environmental stimuli affects the system at large.
Relating the systematic use of manufacturing-enabled form-finding to extrinsic influences affects the
articulation of the sub-locations and the overall system and their orientation to the sun-path and
prevailing wind direction. The resulting surface curvatures and varied levels of system porosity can
then be used to modulate airflow and related ranges of sand-deposition, as well as exposure to
sunlight. The overall flexibility of the system – a product of its material elasticity – enables a higher
responsiveness to the fluctuations of the wind loads. Several dynamics are thus interrelated: airflow,
system deflection and local terrain formation through modulated aggregation, as well as velocity of
airflow, air-borne sand and abrasion of the material assembly. Ultimately the main concern of this
project is the strategic entwining of these time-cycles
AA Diploma Unit 4 (Michael Hensel, Achim Menges)
Aleksandra Jaeschke, Architectural Association, London, 2004-05