In nature, Tessellated Material Systems (TMS) appear convergently across species and at all length scales. Their evolutionary success is based on the ability to unify mechanically opposing properties in one functional system. While the application of tessellations in Design and Architecture was and is focusing on the geometrical and structural benefits, this practice-based PhD project explores a different Design approach shifting the focus from structure to material. The aim of this research is to develop methods for designing hierarchical materials that lead to multi-functionality allowing for context sensitivity.

A workflow towards designing surfaces with distinct kinematic properties  
︎︎︎ back or  research process ︎︎︎

Mechanically rigid elements are bonded to pre-stretched textiles using 3D printing. The textile therein simulates the soft interfacing membrane between the hard plates as observed in natural systems. The textile absorbs the applied tension that arises due to the pre-stretching and transfers it to the entire system. The generated model and workflow can be used to explore the complexity of properties of natural tessellation systems while opening up new areas of application for Design and Architecture.

This practice-based PhD project shall be a contribution to refining our current Design approach from structure to material focused. The aim of this research is to develop a method of designing hierarchical material structures that lead to multi-functionality and allow for context sensitivity. To demonstrate the relevance of applying design driven research methodology I have argued that irregularities and asymmetries in TMS create inherent functional properties that can be productive strategies for constructing adaptive and context aware surfaces. The underlying natural processes responsible for pattern formation can be regarded as functions or programs, which are per definition context specific. Meaning the context of a pattern is an essential parameter to consider. If such context is misunderstood or insufficiently understood, a biomimetic approach alone cannot lead to meaningful designs. The challenge of applying principles of TMS in real word scenarios is therefore not purely technical, but involves the implementation, coordination and evaluation of contextual information – Design practice.

The following categories have been developed to describe the macroscopic structures: Tile Shape, Granularity, Tile to Tile Interaction, and Tessellation Pattern. This study aims to replicate the strategy of hierarchical structural variation between soft interface and hard tiles as observed in natural systems.The gaps between solid tiles are mostly filled with relatively soft (often fibrous) material, due to this structural duality multifunctionality can be achieved. Such a complexity of properties is difficult to simulate digitally (i.e. Finite Element Analysis) to overcome limitations in computer-based simulation I developed analogue prototypes.
Here structural hierarchy can simply be introduced by combining structurally different materials such as jersey textile and 3D printed PLA. The developed workflow relies on two established design techniques: 1st: The parametric pattern generation is performed with Rhinoceros 7 and its plugin Grasshopper, as well as the Kangaroo Physics extension develop by Daniel Piker. 2nd: The simulation of surface kinematics is performed with 3D printing on pre-stretched textiles, as presented by MIT Self- assembly Lab (Tibbits, Skylar 2017).

The computational approach translates the developed taxonomy into parameters to create the functionality for parametric iterations, and the systematical exploration of parameter spaces. In the process of physical prototyping mechanically rigid elements are laminated to pre-stretched textiles using 3D printing. The selected textile (jersey 94% cotton, 6% elastane) therein simulates the soft interfacing membrane between the hard plates as observed in natural systems. It structurally traps surface tension, which after the lamination is applied to the whole system (activation power). Once the tension of the fabric is released, those areas laminated with 3D printed material are structurally reenforced and resist the shrinking force. This duality of properties allows disproportional shrinkage, resulting in three-dimensional surface deformation. The presented technique is able to generate surfaces that transform from plane to dome like morphologies, expressing gaussian curvature.

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