bylayer | hattifatterners
In partnership with Maho Kobayashi and Li Jui Hung
Hattifatterners experiments with additive processes through robotic clay extrusion to construct architectural systems at a micro level. During these experiments, robot speed, extrusion speed, layer thickness and width, and the limitations of clay extrusion forms and strength were tested.
Investigations
The project explored using repeatable forms to create a wall assembly that interacted with natural light, water, and air flow. We chose to experiment with curved forms and loose interlocking techniques due to the ability to manipulate the natural elements. The movement of water on the curved surfaces and the light and air seeping through the gaps were intriguing.The experimenting began with printing the initial forms and measuring them pre and post firing to track the size and shrinkage of the clay in wet and dry forms. This size difference was important to the project, because the pieces needed to fit into each other. They couldn’t fit too tight or lose as it was important there was just enough light, water, and air, but not too much.
Fabrication
Throughout these tests a few key pieces of information became
apparent. With the finger form, the curves were great for transporting water,
but if printed at too harsh of an angle the clay would slump mid print. The use
of a larger print nozzle created a larger bead width and at times allowed for a
slightly sharper angle, but with the larger bead width came the issue of the
clay being too heavy to support itself at an angle.
The interlocking of the puzzle piece form created an opportunity for the structures to interact with light and air. With this concept the largest hurtle was the bead width and the shrinkage that happened when the designs were fired. The initial puzzle piece design was a bit too tight and the prints would fit together before firing, but after firing they would not fit together. If the bead width became too thick, then the tighter areas of the design would start to touch each other mid print and affect the print quality of the object.
The interlocking of the puzzle piece form created an opportunity for the structures to interact with light and air. With this concept the largest hurtle was the bead width and the shrinkage that happened when the designs were fired. The initial puzzle piece design was a bit too tight and the prints would fit together before firing, but after firing they would not fit together. If the bead width became too thick, then the tighter areas of the design would start to touch each other mid print and affect the print quality of the object.
Culmination
The final structure consisted of three different forms that are easily repeatable both horizontally and vertically. From the test findings, a final design was created using curved surfaces that somewhat resembled a puzzle piece and nestled gently into each other. When nestled together the forms still contained large enough gaps to manipulate light and air. Within the central part of these forms was a carved-out cavity that would hypothetically collect water at a larger more realistic scale.Due to the angles of the final forms, each individual structure was fabricated with three separate prints. When trying to print all three parts in a single print, the print failed repeatedly. Breaking the print up at the pinched or thinner points of each structure allowed for a successful print of each part. The final extrusion bead width was five millimeters because it was thick enough to allow for slightly sharper angles, but thin enough where the walls of the design would not touch during the print.