uva school of architecture, design driven manufacturing

DESIGN DRIVEN MANUFACTURINGJ ea n a R i p p l e

University of Virginia | Department of Architecture

A

Publisher

Editors

Research Director

Acknowledgements

Credits

Paper Matters Press | Department of Architecture, University of Virginia

Iñaki Alday, Ryan Carbone

Jeana Ripple

Copyright Texts | By authorCopyright Drawings | By authorCopyright Model Photos | Scott Smith / By authorCopyright Edition | Department of Architecture, University of Virginia

Graphic Design | Jeana Ripple, Ryan CarboneLayout | Jeana Ripple, Ryan CarboneProduction | Jeana Ripple, Ryan Carbone

Printing | Department of Architecture, University of VirginiaISBN: 978-0-9974301-2-7First Edition | March 2016

As co-founder of the Design-Driven Manufacturing initiative at UVA, Jeana Ripple thanks the following for their support: + co-founder Suzanne Moomaw, UVA Urban and Environmental Planning + The Jefferson Trust + The UVA Offices of the Vice Provost and the Vice Provost for the Arts + Cellular Materials International + Gaston + Wyatt + Research Assistants: Tom Bliska, Joshua Aronson + UVA Shops: Melissa Goldman, Steve Warner, Sebring Smith

Architecture, as part of a research institution is a pedagogical program based in social responsibility, critical thinking and innovation. And as a design discipline, architectural innovation is achieved through design research in different ways. We “search” for information, and we “research” creating knowledge, most often on new scenarios through design speculation seriously informed. Rigorous collection of data, spatialized through mapping and diagraming, create the basis for design research. The critical step forward, assuming the risks of proposing future scenarios, is the unavoidable outcome of the creative work of the research teams.

The Research Studio system is the pedagogical innovation that merges instruction with faculty and students research. Two studios in the undergraduate program (3010 and 4010) and another two in the graduate program (7010 and 8010) are focused on profound architectural research aligned with research interests and expertise of the faculty members. The instructors commit for three to five years to sustain a research line, offering a series of Research Studios that take on a variety of relevant contemporary topics in a consistent multi-year research agenda. Students define their personal path through the program, selecting the research studios offered by Architecture faculty (and Landscape Architecture for the graduates), in their own preferred sequence for the fall of the last two years (3010 and 4010 or 7010 and 8010).

The diversity of topics reflects the intellectual diversity of the Department of Architecture of the University of Virginia. Research projects take on urgent international crises such as the changing condition of the Arctic, neglected cultural landscapes in depressed regions, or one of the most pressing urban ecologies challenge in the world (Delhi and its sacred and poisonous Yamuna River). Others work within local conditions, disciplinary inquiries or philosophical and spatial investigations.

Started in 2012-13, these first four years have been especially instrumental for the development of the youngest faculty, raising $529,000 in grants, five awards and two international symposiums. One of the research projects has become the first all-university grand challenge project. The Research Studio system of UVa has proven itself to be invaluable in defining what “design research” means, its potential to reach broader audiences and impact critical contemporary situations, and to redefine the research culture in the design schools.

Charlottesville, Virginia | March 2016

IñAkI AlDAyQUESADA PRoFESSoR AND ChAIR, DEPARTMENT oF ARChITECTURE

DESIGN DRIVEN MANUFACTURING

P R E FAC E

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Jeana Ripple is an architect, founding principal of Ripple Architecture Studio, and Assistant Professor at the University of Virginia. Her background as a professional “white hat” hacker and computer science engineer informs a rigorous attention to detailed complex systems and a willingness to take risks in her approach to design. Her research investigates materials as the intersection of performative and cultural systems. Ripple Architecture Studio projects range from the invention of manufacturing-based material technology to envisioning the factory of the future to regional health and infrastructure solutions. Ripple’s work has won multiple AIA awards and been nationally and internationally exhibited and published. Her teaching was recognized by the 2015 ACSA|AIAS New Faculty Teaching and 2015 BTES Emerging Educator awards. Her prior experience includes work at Studio Gang Architects where she led the design team for the MoMA “Foreclosed” exhibition, a structurally innovative residence in Manhattan Beach, and a 91-acre urban park in the center of Chicago’s museum campus.

JEANA RIPPlE, AIA, lEED APaSSISTaNT pROFESSORDEpaRTmENT OF aRchITEcTuRE

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DESIGN DRIVEN MANUFACTURING 3

ST U D I O T E A M

American cities are struggling to reconcile the changing face of industry and anticipate trends and opportunities for the future. Most cities face the combined challenge of abandoned industrial fabric and a need for new adaptable infrastructures of production. Despite the recent downturn in jobs and loss of domestic industry, the United States remains among the world’s largest manufacturing economies.

Manufacturing directly employs roughly 12 million Americans. Breakthroughs in technology and advanced manufacturing processes spill over into the productivity of the service and agricultural economies. American public and private partnerships are investing in training, education, and tax incentives to promote what they describe as “advanced manufacturing”—a confluence of high-level technology, design, and innovation.

How do these infrastructures and initiatives interface with the built environment? How can regional skills and material resources influence the production of architecture? How does access to real-time performance data and manufacturing expertise change the design process? The prospect of the future calls for more innovation.

Manufacturing regions in Virginia function as a case study for examining the reciprocal influence between material performance (new technology, manufacturing processes, material hybrids, simulation and testing capabilities) and material culture (networks of expertise, financial infrastructures, limited resources). This studio supports a broader Design-Driven Manufacturing Initiative at the UVA School of Architecture, launched in 2013 by Jeana Ripple and Suzanne Moomaw. We are suggesting a new role for designers in the manufacturing economy by examining the changing geography of manufacturing, collaborating with local municipalities and industries, building upon existing R+D, designing, simulating, prototyping, and testing.

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MANUFACTURING PROCESSES

GEOGRAPHIES OF MANUFACTURING

MATERIAL OPPORTUNITY

GENERATIVE TECHNOLOGY

DESIGN DRIVEN MANUFACTURING 5

R E S E A R C H D R I V E RS

GEOGRAPHIES OFMANUFACTURING

Manufacturing regions largely follow patterns of physiography and resulting clusters of resources. Evidence of this relationship between industry and landform is traced locally, through landform, lines of transportation, and urban manufacturing hubs. For example, manufacturing centers on the east coast are largely “fall line” cities, following the geomorphological break between rock and coastal plane where river rapids typically occur. Therefore material must be pulled from shipping ports, processed, and transferred to rail lines. How can fundamental connections between physical space and manufacturing influence our design of infrastructure going forward?

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Ripple Architecture Studio + Suzanne Moomaw | DESIGN DRIVEN MANUFACTURING

APPALACHIAN PLATEAUS

COAL, LUMBER

VALLEY AND RIDGE

COAL, LUMBER, FURNITURE

BLUE RIDGE

AGRICULTURE, FURNITURE, COATINGS

PIEDMONT BELTS

AGRICULTURE, FURNITURE

COASTAL PLAINS

SHIP-BUILDING, METAL-WORKING

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DRIVER 1 | gEogRaphIEs of manufactuRIng

Ripple Architecture Studio + Suzanne Moomaw + Callahan, E | DESIGN DRIVEN MANUFACTURING

D R I V E R 1 | G E O G RA P H I E S O F M A N U FACT U R I N G

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GENERATIVE TECHNOLOGY

Architects have long fostered close partnerships with the manufacturing industry. But today’s performance-aided design technology makes a nuanced understanding of material performance more immediate during the design process. How can the built environment adapt to complex environmental conditions by creating responsive material building blocks? How can we expand our ideas of simulation to include cultural factors such as material resource, networks of expertise, and financial infrastructures?

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Ripple Architecture Studio | DESIGN DRIVEN MANUFACTURING

DRIVER 2 | gEnERatIVE tEchnoLogY

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Modules vary according to structural load distribution. Student-fabricated mock-ups are used to test variation and performance parameters.

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Granados, S + Grotz, S +Friedrich, A | DESIGN DRIVEN MANUFACTURING

Material systems perform technically according to climatic and structural parameters, and architecturally according to programmatic and aesthetic aspirations.

D R I V E R 2 | G E N E RAT I V E T E C H N O LO G Y

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Jeana Ripple | DESIGN DRIVEN MANUFACTURING


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Kochuba, C + Craddock, E | DESIGN DRIVEN MANUFACTURING

Material systems take advantage of simple metalworking techniques from local manufacturers, while testing multiple performance parameters digitally and physically.


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The studio’s methodology expands architectural performance objectives to include efficient ties to manufacturing economies, material resources, and building performance. We collaborate with manufacturing experts, material scientists, and industrial planners. As students work with local manufacturing partners, we couple advanced simulation technology with the expertise of streamlined manufacturing to produce complex performance-efficiency rather than complicated fabrication.

MANUFACTURING PROCESSES

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Jeana Ripple + Lindsey Hepler | DESIGN DRIVEN MANUFACTURING

DRIVER 3 | manufactuRIng pRocEssEs

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SIDE

TOP

FRONT

d = 16”

~15.13”24”

12”

12”

12”

FULL PIECESx 50

HALF PIECESx 12

~ 7.44”

d = 16”

d = 15.13”

NOTCHES

~ 1.3” LONG~. 1875” WIDE

NOTCHES

~ 1.3” LONG~. 1875” WIDE

With an efficient cut and assembly pattern, the constructive corrosion project explores rusts expansion as a means to a self-welding facade system. Curved pieces are optimized to direct water flow, accentuating the varied color patterns created through weathering.

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O’Hara, K + Scott, L / Jeana Ripple | DESIGN DRIVEN MANUFACTURING

D R I V E R 3 | M A N U FACT U R I N G P R O C E SS E S

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Diffusion Screen utilizes the techniques of local metal manufacturers, taking advantage of the smooth, lightweight, corrosive-resistant qualities of aluminum. As an alternative to the typical gutter system, where water is rapidly collected from rooftops and scoured across impermeable ground surfaces, this system slows water, channeling it across the facade, and allowing it to filter into the aquifer below.

PRESSPLACE REMOVE

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Kochuba, C + Craddock, E | DESIGN DRIVEN MANUFACTURING


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SHIPBUILDING INDUSTRY CELLULAR METALS

Bend

Shape Evolution

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SCALE: 1” = 5”

SCALE: 1” = 5”

FULL COLLAPSE

ORIGINAL DESIGN FOLDED

WEAK POINT:box collapsesand will not maintain structural integrity without secondary support system

QUICK FIX

PROBLEM:additional, seperate structural system defeats oringinal intent to create easily stored, collapsable furniture.

REDESIGN FOLDED

STRENGTH

STRONG BOX:box remains strong and is able to collapse into a relatively flat form for easy storage with no additional structure neces-sary.

ORIGINAL DESIGN FOLDED

OVERLY COMPLICATED:while the collapse design was success-ful, the system was overly complicated and entirely too difficult to assem-ble.

REDESIGN FOLDED TOP VIEW MECHANICS

STRENGTH TEST:can hold 1 walrus

slight deformation

STRUCTURE

RESPONSE TO VARIABLE CONDITIONS

VARIABLE SHUTTER METAL ORIGAMI

x2

per box

x2

x2

x24

4 boxes = 1luci

By utilizing the inateproperties of steel:

LUCI is strong yet thin,holding its own againstthe weight of the user

The tight bond betweenthe welded hinges and

the steel is unbreakable

And most importantly,LUCI’s steel is

impervious to the flame

ASSEMBLY

Current

Ideal

Step 1plasma cut

Step 2grind/smooth

Step 3weld

Step 1Water Jet Cut

new cut pattern

hinges integrated

Step 2form hinges

1 2

3 4

Step 3pin and seal hinges

SCALE: 1” = 5”

SCALE: 1” = 5”

SCALE: 1” = 10”

SCALE: 1” = 10”

ERGONOMICSCORNERS

SHARP

R 1”

R .5”

HANDLES

AVG. 4”

SHARP SCALE

5”

1.5

”

SCALE

2

20”

20”

18-2

0”

1 VS

18”

36”

30”

30”

2 3

36”

IN USE

ROUNDED

ROUNDED

ORIGINAL OPTIMIZED

lINKED

INTERCHANGABLE

UNIVERSAL

COMPACT

VS

THE CHAMPION THE BLEACHER THE STEP LADDER THE NOTHE STRADDLETHE CHAIR THE SOAP BOX

?

CONFIGURATIONS

Callahan, E + Bost, J + Eldredge, S | DESIGN DRIVEN MANUFACTURING


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OPENGROUNDS ACOUSTICS

RACHEL BRONDSTATER & COURTNEY KEEHAN

WALLS CEILINGPLAN SECTION

CONCAVE CONVEX IRREGULAR

DIFFUSES SOUND FOCUSES SOUND DIFFUSES SOUND EVENLY

WHA

T WE K

NOW

SOUND-SURFACE INTERACTION SOUND-ROOM INTERACTION

STUDY PRESENTATIONADMIN STUDY PRESENTATIONADMIN

USE O

F SPA

CE

ACOUSTIC DIVISION OF SPACE

DESI

GN CR

ITER

IA

ADDRESSING CLIENT NEEDSCREATION OF A SERIES OF SPACES THAT ALLOW FORDIFFERENT ACTIVITIES TO OCCUR AT ONCE

DEVELOPMENT OF A DESIGN THAT INFLUENCES BEHAVIOR

DESIGN INTERVENTIONACOUSTIC FABRICS THAT DEFINE A SERIES OF SPACES INOPEN GROUNDS THROUGH THE ENHANCEMENT OF SOUND CONTROL AND REDIRECTION

THE DEFINITION OF SPACE OCCURS WITHOUT THE CONSTRUCTION OF BARRIERSTHAT WOULD TAKE AWAY FROM THE OPEN ATMOSPHERE UNIQUE TO THEROOM

ACOUSTIC METAL MESH ACOUSTIC CHAMBER FABRIC

CELLULAR STRUCTURE PAPER CELLULAR DESIGNS METAL CELLULAR DESIGNS

HONEYCOMB HEXAGON PENTAGON

STRENGTH & STRUCTURE REGULARITY VARIABILITY

CON

NEC

TIO

N

BEN

DIN

G

ONE MODULE IDEAL FOR MANUFACTURINGASSEMBLY

9”

9”

TAB

SLOT

CONNECTION SYSTEM

CONVEX SURFACETHE USE OF CONVEX SURFACES IN AN IRREGULAR PATTERN RESULTS IN EVENLY DIFFUSED SOUND THROUGHOUT THE SPACE.

The modules can also beassembled with a rangeof folded and unfoldingunits. This results in an undulating fabric suspensionthat curves down towardsthe back of the audiencespace to contain soundwaves within the space.

UNDULATING FABRIC

The semi-curved suspension of the modulestransending towards the back of the audiencespace keeps sound from the performance to onede�ned area, allowing for additionally spaces inthe open room to countinue to be used for otherfunctions.

INTERVENTIONPLACED WITHIN AREA USUALLY USED FOR PRESENTATIONS

ABSORPTION CHAMBER SOUND TRAP

CELL

ULAR

STRU

CTUR

EFA

BRIC

ATIO

N AN

D M

ATER

IAL P

ROPE

RTIE

SSY

STEM

FUNC

TION

AT B

UILD

ING

SCAL

EAB

SORP

TION

CELL

ULAR

STRU

CTUR

EFA

BRIC

ATIO

N AN

D M

ATER

IAL P

ROPE

RTIE

SSY

STEM

FUNC

TION

AT B

UILD

ING

SCAL

EAB

SORP

TION

BUDG

ET

CHAMBER ABSORPTION MATERIAL

CORK ARCHITECTURAL SCALE

EXPANSION

SOUND SOURCE PROJECTION

STEEL WOOLSTACKING EFFECT

SOUND DIFFUSION AND REFLECTION

SOUND ABSORPTION

$100

.016” THICK FLASHING SHEET METAL4 FEET X 5 FEET

$230 $240 $100

20 GAUGE ALUMINUM SHEETS36 INCHES X 48 INCHES

8 SHEETS

STEEL WOOL SHEETS9 INCH X 11 INCH SHEETS$3 PER SHEET, 33 SHEETS

AUDIO TOOLS APP TOTAL

$670

Keehan, C + Brondstater, R | DESIGN DRIVEN MANUFACTURING


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MATERIAL OPPORTUNITY

In partnership with economic development students, the studio tackles material foci on the basis of economic potential. For example, the exodus of Virginia tobacco and furniture industries necessitates the reapplication of skills and infrastructures. Bamboo offers a potential replacement crop that is on par with regional timber industries according to material output while thriving in diverse climatic regions and sequestering far more carbon. If the labor involved in laminated bamboo material production is a deterrent to domestic operations, what alternate assembly systems can make more efficient use of raw or minimally processed bamboo?

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local furniture industry partners, Gaston + Wyatt

DRIVER 4 | matERIaL oppoRtunItY

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D R I V E R 4 | M AT E R I A L O P P O RT U N I TY

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Cally Bryant | DESIGN DRIVEN MANUFACTURING

D R I V E R 4 | M AT E R I A L O P P O RT U N I TY

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University of Virginia | Department of Architecture

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uva school of architecture, design driven manufacturing

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