Sculptural Architecture
Algorithmic Design Implementation, CAD, Manufacture and Installation
This unique sculptural soffit consists of over 800 different 1.2mm thick highly poished pressed panels created by parametric 3D modelling geometry. The CAD/CAM digital fabrication process created two 30m long sculptures which were laser cut, CNC folded and assembled accurately to within 10mm over the entire distance.
From a supplied 3D surface model, we used a generative algorithm to take the 800-panel surface form and:
Identify each panel with specified preface (size and location)
Flanges to which each panel will mate (height with variability)
Hanging points for the installation (location, hole size and edge distance)
Fixing holes for each/every fastener (multi-location, with size and qty variability)
Material ‘relief’ for bending and cutting operations (variability in the angle of flange)
Collision detection to inform us of panels where flanges are expected to intersect
Minimum angle detection for highlighting problematic panels either to assemble or bend
What would have taken weeks to model, check and confirm was resolved in a matter of days in writing the algorithm and minutes for the execution of the updated model with final geometry and with more accuracy.
The ‘trimmed’ panel geometry was then exported from Rhino to Solidworks for conversion to sheet metal where the material thickness was applied, corner reliefs added and the 3D panel ‘unfolded’ (with allowance for material stretching and compression) to create a 2D cut file for laser cutting and finally CNC bending.
