(re)modular design - Bachelor-Thesis
Task
The principles of modularity and discrete design provide a concept to rethink traditional construction. This Thesis should contribute a part to this discussion, by proposing a modular system that can adapt to different structural requirements. To prove the concept of the modular system, several demonstrators with different requirements should be designed. The designs should thereby follow the way from a digital model to a physical model. The research question of this thesis can be stated as the following:
“How does a modular system look like in that the modules are capable of dealing with different functional and structural requirements, occurring in a building?”
Modularity
The concept of modularity is common in various disciplines, that range from computer science to product design, economic systems, and architecture. Despite the intensive use of the concept, there is no clear definition of modularity. In common sense, modularity can be defined as
the degree to which a system’s components may be separated and recombined, often with the benefit of flexibility and variety in use. [1]
As modularity is always a driver for the efficiency of a system, a modular system should decrease the cost per module, by maintaining high flexibility and adaptability to varying tasks, as well as the possibility to add new parts to the system. Prefabrication, standardization, and low complexity of modules can decrease the cost per module. To maintain the adaptability of a system to varying tasks, standardized connection interfaces between modules a crucial.
Discrete Design
In recent years a new way of thinking about modular systems rose. The computational design allowed for creating continuous surfaces and geometries that afterwords get divided into parts to be manufactured. The theory of discrete design flips this top-down approach of an overarching form, that gets divided into parts, into a bottom-up approach where the form erases from the part itself. A design is not defined by a continuous surface but by a combination of parts following combination rules. Elements in a discrete design are valuable for themself and often their connectivity is embedded, enabling them to constantly add up to the aggregation.
Bearbeitende:
Leon Wietschorke
WiSe 20/21 | FG DDU, Prof. Dr.-Ing. Oliver Tessmann, Bastian Wibranek, TU Darmstadt
[1] Extracted from: Modularity, Wikipedia, https://en.wikipedia.org/wiki/Modularity#cite_note-MWModular-1, accessed 26.02.2021
Design Process
Geometrical Approach
To develop a modular system several considerations need to be made. One of the key elements is the module geometry as it mainly defines the appearance of the system. On the way to finding the right geometry for my modular system, I experimented with several other geometries.
As a result of the discussion on module geometry, I propose these five geometries. These are beam-like elements with different lengths. The ends are cut at a 45° angle that highlights the linear orientation of the modules. The Cross-section of the modules differs as well and provides a change in the granularity of the modules. As this is a generic geometry the module length and width can change, these five proposed dimensions are a suggestion for the granularity of a modular system.
Connection Interfaces
The final connection interface is an adaptation of the sliding dovetail. By adding an extra straight section the connection cannot only take a dovetail but can also safely secure board elements. This allows for different use of the connection interface and possibilities to implement new modules.
The groove can be cut with a router and does not rely on high-tech machines. Similar to the groove is the tongue manufactured, it can either be cut out of the whole or added up with different bars.
Module Logic
This small-scale module exemplifies the connecting principles of the system. Each module has positive and negative connectors that can slide into each other. The angle in the grooves restricts the movement of the parts by limiting their degree of freedom, by also providing a change of direction for the system.
Topology Optimization
Topology Optimization is a shape-optimizing method that optimizes the performance of a system. With a set of load, support, and boundary conditions the optimization is performed, by removing material to a minimum, by still maintaining the structural stability of the system. The three main parameters, target density (TD), resolution (Res), and iterations(It), adjust the outcome of the optimization.
Orientation Constraint Aggregation
The density of the topology optimization can be translated into a field. This field is the basis for the distribution of modules for the plugin wasp. The higher the density of the topology optimization the more likely a module to be placed at this position. The field can be adjusted to specify which module is placed at which part of the aggregation. Another aspect to control the placement of the modules in the aggregation is to define aggregation rules. These rules define which connections can be used. A basic rule for the modular system is that only grooves can connect to tongues, to provide structural stability.
The orientation of the modules is constrained so that only the blue modules are allowed to be placed at an angle. All other modules keep a horizontal orientation and thereby highlight the linear orientation of the modules and the aggregation itself.
Design Proposal
Wood Lifecycle
Wood is a durable material that can be recycled and reused but needs to be stored at different stages of its lifetime. After getting harvested and processed it gets stored until it's used for construction. Also, wooden-beams that are saved from old half-timbered or other buildings are stored until they are reused. The material storages take a lot of space that can’t be used in other ways. Is there a chance of not only storing the material in piles, but creating architecture?
Architecture as storage
By using the modular system proposed in this thesis timber can be stored as a building. The combination of several elements forms a building that not only fulfills the function of a building but also as material storage. And as it is a modular system, modules can be taken out of the buildings to construct new structures. To define where modules are structurally needed and where they are only some sort of cladding the concept of Typology Optimization is used. The Topology optimization defines thereby the minimum filling level of the material storage.
Ever changing Appearance
The constant change of the filling level of the storage directly affects the look of the building. New parts seem lighter than older ones that are bleached by the sun. This not only gives the building a dynamic appearance but also highlights which parts are newly added.
Architectural Interpretation
From the abstract concept of a modular system based on a geometrical and interface exploration to a building that is not only a room to stay in but also a storage for the modules themself. The constant change gives the structure character and diversity. It showcases without any explanation the principles of changing storage.
The building in this case follows the flow of the mountain by descending parallel to the mountain and thereby revealing step by step the view into the wilds. A moment of longitudinal extension of the mountain through the building follows the principle and orientation of the modules.
Multi-use modules
To show the possibilities of the modular system three different buildings are aggregated with the set of modules. Starting with an enclosed room as the material storage. By taking parts from this storage a plattform, as well as a pavilion, can be aggregated. The storage keeps its structural stability through the module distribution by the topology optimization.
Process for (re)modular-design
The proposal for (re)modular design extends the life span of timber products. Wooden beams from half-timbered or other wooden buildings can be reused as a building material instead of being recycled. They, therefore, get manipulated with simple hand tools to fit into the modular system and are then added to the material storage. This material storage is a building itself constructed with the modular system. Elements are added to the building after the principle of topology optimization to guarantee structural stability at any time. If elements are needed for new constructions they can be taken from the module storage. This enables constant change not only in the appearance of the buildings but also in the density of buildings.
Model 1:10
To validate the modular system I produced the modules in different scales. At first on a scale of 1:10. These modules have been 3D-printed and can be aggregated in various configurations. The scale allows for a large set of modules and therefore a good exploration of the system itself.
Model 1:1
In the second step, I manufactured the modules on a scale of 1:1. This allowed me to prove the proposed way of manufacturing with simple hand tools. The tools needed for manufacturing one module are a router with different cutters, a parallel guide, a folding ruler, an angle, a pencil, a screw clamp, and a handsaw.
With these three modules, I was able to prove the production process as well as the connectivity of the modules.
Model Manufacturing
The video showcases the manufacturing of a model on the scale of 1:1. Only simple hand tools are needed to get from a simple wooden beam to the complex module.