01 Fakultät Architektur und Stadtplanung

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Open Access
Fibrx rocking chair : design and application of tailored timber as an embedded frame for natural fibre-reinforced polymer (NFRP) coreless winding
(2023) Pittiglio, Alexandra; Simpson, Ailey; Costalonga Martins, Vanessa; Dahy, Hanaa
The building industry needs to innovate towards a more sustainable future and can do so through a combination of more renewable material choices and less wasteful fabrication processes. To address these issues, a hybrid material and fabrication system was developed using laminated timber veneer and natural fibre-reinforced composites (NFRPs), two materials that are leveraged for their potential of strategic material placement in additive processes towards programmed material behaviour and performance. The main contribution is in the hybrid fabrication approach, using thin, bent laminated veneer as an embedded frame for coreless filament winding of NFRP, which removes the need for temporary, wasteful formwork that is typically required to achieve structurally performative bent timber or FRP elements. Integrative methods are developed for the design, simulation, and fabrication of a rocking chair prototype that illustrates the architectural potential of the developed fabrication approach.
Open Access
Tensegrity FlaxSeat : exploring the application of unidirectional natural fiber biocomposite profiles in a tensegrity configuration as a concept for architectural applications
(2024) Renner, Markus; Spyridonos, Evgenia; Dahy, Hanaa
Material selection is crucial for advancing sustainability in the building sector. While composites have become popular, biocomposites play a pivotal role in raising awareness of materials deriving from biomass resources. This study presents a new linear biocomposite profile, fabricated using pultrusion technology, a continuous process for producing endless fiber-reinforced composites with consistent cross-sections. The developed profiles are made from flax fibers and a plant-based resin. This paper focuses on the application of these profiles in tensegrity systems, which combine compression and tension elements to achieve equilibrium. In this study, the biocomposite profiles were used as compression elements, leveraging their properties. The methods include geometrical development using physical and digital models to optimize the geometry based on material properties and dimensions. A parametric algorithm including physics simulations was developed for this purpose. Further investigations explore material options for tension members and connections, as well as assembly processes. The results include several prototypes on different scales. Initially, the basic tensegrity principle was built and explored. The lessons learned were applied in a final prototype of 1.5 m on a furniture scale, specifically a chair, integrating a hanging membrane serving as a seat. This structure validates the developed system, proving the feasibility of employing biocomposite profiles in tensegrity configurations. Furthermore, considerations for scaling up the systems to an architectural level are discussed, highlighting the potential to enhance sustainability through the use of renewable and eco-friendly building materials, while promoting tensegrity design applications.
Open Access
Bio-inspired integrated actuation and variable stiffness for compliant mechanisms
(Stuttgart : Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart, 2022) Mader, Anja; Knippers, Jan (Prof. Dr.-Ing.)
Due to advantages, such as a low mechanical complexity, low weight, and the absence of friction of wear, compliant kinetic systems are increasingly used, including for large-scale applications like facade shading. To exploit the advantages also for the actuation, bio-inspired joint-free actuators were developed within two case studies. Both actuation principles proved their potential to actuate 2-dimenional compliant devices within physical prototypes. Additionally, adaptive stiffness concepts were developed to potentially increase the load bearing capability temporarily. Following a biomimetic top-down approach, the leaf folding of the model plant Sesleria nitida caused by turgor variations within large bulliform cells was investigated using a FEA. The turgor pressure opens the leaf against a present pre-stress. Turgor and volume variation within the bulliform cells that result from fluctuations in water availability generate forces high enough to fold and unfold the leaf. This pressurize-based actuation principle is abstracted to a technical cellular structure constructed from GFRP (glass fibre-reinforced plastic) cells with compliant hinges. An increase in inner cell pressure causes a reconfiguration of the cell and an overall bending motion of the actuator. At the same time, thin-walled plant tissues show a strong turgor dependent stiffness. By adding a second, counteracting cell row that decouples deformation from absolute pressure, this can be realized also in the technical actuator. The bending motion is now determined by the pressure ratio, and the stiffness by the pressure magnitude. Within physical and numerical experiments, the stiffness of a cellular actuator increases by a factor of 2.5 at a pressure increase of 1 bar. Within the second case study, a pneumatic actuation that is fully integrated into a GFRP laminate was developed. The wing vein ultrastructure of Graphosoma lineatum italicum inspired the laminate built-up of the GFRP with an integrated pneumatic pouch. By surrounding the pouch with an elastomeric layer, analogous to the resilin bearing endocuticle within the biological model, a delamination of the laminate layers is prohibited. The approach allows a simple fabrication, and slender, homogenous appearance. Upon an internal pressure increase, the eccentric placement of the pneumatic pouch and the greater compliance of the thinner layer results in a rotation into that direction. This way a folding motion is realized by a pouch placed in a hinge zone of greater compliance. A quasi-uniform bending is created by placing a segmented large-surface pouch integrated in a plate of distributed compliance. The adaptive stiffness is added by an antagonistic actuator set-up inspired by opposing muscles used to control and stiffen skeletal joints. For a GFRP plate an increase in stiffness of 60% was achieved at 1.8 bar internal pressure.
Open Access
Bio-modules : mycelium-based composites forming a modular interlocking system through a computational design towards sustainable architecture
(2023) Abdelhady, Omar; Spyridonos, Evgenia; Dahy, Hanaa
In a resource-constrained world, raising awareness about the development of eco-friendly alternative materials is critical for ensuring a more sustainable future. Mycelium-based composites (MBC) and their diverse applications are gaining popularity as regenerative, biodegradable, and lightweight alternatives. This research aims to broaden the design potentials of MBC in order to construct advanced systems towards a novel material culture in architecture. The proposed design method intends to explore the design and fabrication of small-scale components of MBC to be applied in modular systems. Mycelium-based modular components are being developed to fulfill the geometrical requirements that allow for the creation of a lightweight system without additional reinforcement. The modules are linked together using an interlocking system. Through computational design and form-finding methods, various arrangements of the modules are achieved. An initial prototype of five modules is created to demonstrate the ability of the system to form various geometrical configurations as a result of the used workflow. The proposed application aims to expand the scope of the use of mycelium-based composites in modular systems and to promote architectural applications using bio-based composite materials.
Open Access
Compliant folding : design and fabrication methodology for bio-inspired kinetic folding mechanisms utilized by distinct flexible hinge zones
(Stuttgart : Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart, 2021) Körner, Axel Hannes; Knippers, Jan (Prof. Dr.-Ing.)
Within the larger context of bio-inspired compliant mechanisms for architectural applications and adaptive building envelopes, this thesis aims for the establishment of a design and fabrication framework for bio-inspired compliant folding mechanisms, utilized by distinct flexible hinge-zones. This includes a methodological design approach, consisting of the abstraction and classification of biological folding mechanisms, as well as a sequential abstraction process of underlying working principles regarding kinetic behaviour, materialisation, and actuation strategies. Furthermore, the geometric adaptability and the design space of the established folding mechanisms has been evaluated, especially related to the applicability to different tessellation patterns for double curved surfaces. The insights built the basis for the development of a series of technical applications on a demonstrator level. The functional case studies serve not only as basis to test and evaluate the established design framework, but also to define, test and assess various fabrication and materialisation strategies, as well as actively controlled actuation principles. The first chapters provide a contextualisation of the topic within the larger architectural discourse and give an overview of the background which has influenced the presented research, including biomimetic architecture, compliant mechanisms and suitable materials. The section concludes with a presentation of current research challenges within the field of kinetic and adaptive building envelopes and introduces a series of sate of the art projects. Chapter three contains the publications about the development of the four demonstrator projects Flectofold, Flexafold, Arch(k)inetic and the ITECH Research Demonstrator 2018-19 and relevant investigations which built the basis for this thesis on the topic of bio-inspired compliant folding mechanisms. Chapter four and five conclude the thesis with a summary and critical reflection of the results, as well as the discussion of potential future developments within the topic of compliant mechanisms for adaptive building envelopes.
Open Access
Structural optimization through biomimetic-inspired material-specific application of plant-based natural fiber-reinforced polymer composites (NFRP) for future sustainable lightweight architecture
(2020) Sippach, Timo; Dahy, Hanaa; Uhlig, Kai; Grisin, Benjamin; Carosella, Stefan; Middendorf, Peter
Under normal conditions, the cross-sections of reinforced concrete in classic skeleton construction systems are often only partially loaded. This contributes to non-sustainable construction solutions due to an excess of material use. Novel cross-disciplinary workflows linking architects, engineers, material scientists and manufacturers could offer alternative means for more sustainable architectural applications with extra lightweight solutions. Through material-specific use of plant-based Natural Fiber-Reinforced Polymer Composites (NFRP), also named Biocomposites, a high-performance lightweight structure with topology optimized cross-sections has been here developed. The closed life cycle of NFRPs promotes sustainability in construction through energy recovery of the quickly generative biomass-based materials. The cooperative design resulted in a development that were verified through a 1:10 demonstrator, whose fibrous morphology was defined by biomimetically-inspired orthotropic tectonics, generated with by the fiber path optimization software tools, namely EdoStructure and EdoPath in combination with the appliance of the digital additive manufacturing technique: Tailored Fiber Placement (TFP).
Open Access
Co-design methods for non-standard multi-storey timber buildings
(2023) Orozco, Luis; Krtschil, Anna; Wagner, Hans Jakob; Bechert, Simon; Amtsberg, Felix; Knippers, Jan; Menges, Achim
To meet climate change goals and respond to increased global urbanisation, the building industry needs to improve both its building technology and its design methods. Constrained urban environments and building stock extensions are challenges for standard timber construction. Co-design promises to better integrate disciplines and processes, promising smaller feedback loops for design iteration and building verification. This article describes the integrated design, fabrication, and construction processes of a timber building prototype as a case study for the application of co-design methods. Emphasis is placed on the development of design and engineering methods, fabrication and construction processes, and materials and building systems. The development of the building prototype builds on previous research in robotic fabrication (including prefabrication, task distribution, and augmented reality integration), agent-based modelling (ABM) for the design and optimisation of structural components, and the systematisation of timber buildings and their components. The results presented in this article include a functional example of co-design from which best practises may be extrapolated as part of an inductive approach to design research. The prototype, with its co-designed process and resultant flat ceilings, integrated services, wide spans, and design adaptability for irregular column locations, has the potential to expand the design potential of multi-storey timber buildings.
Open Access
Integrative structural design of non-standard building systems : coreless filament-wound structures as a case study
(Stuttgart : Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart, 2023) Gil Pérez, Marta; Knippers, Jan (Prof. Dr.-Ing.)
Our society is experiencing the emergence of novel nonstandard building systems unlocked by digital technologies in the building sector. The utilisation of computational design processes and digital fabrication, coupled with the exploration of new materiality, bring the potential to break with conventional ways of building. However, they also demand new ways of designing and proving the structure's safety. This dissertation aims to develop an integrative structural design methodology and workflow to design, optimise and validate non-standard building systems. Therefore, a multiscale, digital-physical approach is proposed, which combines structural simulation with small-scale models and material testing, allowing the structure's optimisation and proof of safety. The first two chapters explain the research motivation, objectives and contextualisation. Historical remarks are given to understand the evolution of structural design and the key aspects that created innovation and non-standard systems in the past. Coreless filament winding (CFW) is also introduced here as a representative example of non-standard building systems. Chapter three contains the publications that describe the development of the integrative structural design methodologies through coreless filament wound structures as a case study. All the publications are supported by CFW specimens or full-scale built demonstrators, including BUGA Fibre Pavilion, Maison Fibre and LivMatS Pavilion. Chapters four and five summarise the results, generalising the workflow from CFW structures to non-standard building systems into four sub-methods: multi-level modelling and evaluation; structural characterisation; integrative design; and optimisation and safety verification. The discussion locates the integrative structural design in the historical context and analyses the strategies to prove the safety of other non-standard systems. The conclusion emphasises the potential of this methodology to shorten the gap between research and industry, facilitating the realisation of innovative structures.
Open Access
Topology-driven form-finding : interactive computational modelling of bending-active and textile hybrid structures through active-topology based real-time physics simulations, and its emerging design potentials
(Stuttgart : Institut für Tragkonstruktionen und Konstruktives Entwerfen, Universität Stuttgart, 2020) Suzuki, Seiichi; Knippers, Jan (Prof. Dr.-Ing.)
The inherent relation between aesthetic qualities and structural efficiency inherent on bending-active and textile hybrid structures is associated with a vast range of design opportunities for generating innovative architectural solutions. Exploring those opportunities is a non-trivial task demanding to expand outside current geometric modeling paradigms and develop an insightful and methodological simulation-based design practice. Considering that dynamic methods, such as Particle Systems (PS) and Dynamic Relaxation (DR), have become an important research trend with major advances only focused on speeding up numerical convergence, the main focus of this work is to develop a comprehensive approach for enabling topologic transformations with real-time physics named topology-driven form-finding that, during conceptual stages, can serve to extend design spaces by improving modeling freedom. A general introduction to bending-active and textile hybrid structures is presented in chapter 2. The following chapter then serves to introduce basic principles of PS and DR methods with an overview of mechanical formulations and integration schemes used throughout this work. Chapter 4 introduces the theoretical framework regarding the development of a generic topologic model with geometric and mechanic embeddings for the implementation of PS models supporting topologic transformations on the fly. Chapter 5 proceeds with the presentation of implementations along with a description of design and modeling implications. Different case studies in which the conceptual design development has been conducted via topology-driven form-finding approaches are presented in chapter 6. Finally, this thesis concludes with a discussion of methods and models developed, and a number of recommendations for future research.
Open Access
Mycomerge : fabrication of mycelium-based natural fiber reinforced composites on a rattan framework
(2022) Nguyen, Mai Thi; Solueva, Daniela; Spyridonos, Evgenia; Dahy, Hanaa
There is an essential need for a change in the way we build our physical environment. To prevent our ecosystems from collapsing, raising awareness of already available bio-based materials is vital. Mycelium, a living fungal organism, has the potential to replace conventional materials, having the ability to act as a binding agent of various natural fibers, such as hemp, flax, or other agricultural waste products. This study aims to showcase mycelium’s load-bearing capacities when reinforced with bio-based materials and specifically natural fibers, in an alternative merging design approach. Counteracting the usual fabrication techniques, the proposed design method aims to guide mycelium’s growth on a natural rattan framework that serves as a supportive structure for the mycelium substrate and its fiber reinforcement. The rattan skeleton is integrated into the finished composite product, where both components merge, forming a fully biodegradable unit. Using digital form-finding tools, the geometry of a compressive structure is computed. The occurring multi-layer biobased component can support a load beyond 20 times its own weight. An initial physical prototype in furniture scale is realized. Further applications in architectural scale are studied and proposed.

01 Fakultät Architektur und Stadtplanung

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