Tectonics of Differential Growth. Folds in Additive Fabrication and Moulding for Architectural Design

Abstract

Differential growth is a process of volumetric expansion with spatially uneven intensity, which results in appearance of folds and is an infinite source of patterns in nature. Examples of differential growth are particularly prevalent in epithelial tissue. The paper proposes to use algorithms simulating differential growth for additive fabrication of moulding of architectural structures. The project starts with a research of folding at the level of epithelia cells and proposes a geometrical model simulating the process. Chosen geometrical approach has the advantage of continuity and closeness of any horizontal cross section, which allows for rapid additive fabrication as well as for use as a mould. Since one of the main issues of additive fabrication at construction scale is the problem of keeping production time down while keeping the detail scale required for the finish, the authors propose 3D printing moulds with extremely thin walls. These moulds are later filled with liquid material after hardening of which the structural qualities are reached. Small thickness of the walls is essential for the production speed, and its vulnerability to deformation is solved by simultaneous filling of the mould from both sides, with materials of similar density. The outer material is later extracted and recycled. Project results in production of several prototypes, which demonstrate the structural, spatial and aesthetical qualities of the approach. Project unravels and explores the potential of the surface maximization in relation to environmental impact of the architecture, in particular heat dissipation.