FlexMaps 2.0: a bending active structure with optimized spiral mesostructures 

Francesco Laccone, Luigi Malomo, Paolo Cignoni (ISTI-CNR)

Nico Pietroni (UTS School of Computer Science [FEIT])

Dane Voorderhake, Lucy Wang, Nathan Gonsalves, and Tim Schork (UTS School of Architecture [DAB])

Bending-active structures are an inexpensive and efficient structural system that can produce curved shapes out of flat or straight elements. While several techniques are available to generate these structures, only a few recent works make it possible to fully control the geometry by imposing a predefined target shape. In this context, the FlexMaps algorithm [Malomo et al. 2018] has demonstrated good performances in generating complex-shaped, efficient, and lightweight structures [Laccone et al. 2019]. The FlexMaps algorithm relies on locally optimizing mesostructured panels, namely spiral patterns that can bend to assume double curvature.

The stiffness of a panel can be tuned by modifying the geometry of each spiral. The pattern is optimized to match the target shape once assembled. So even non-developable complex shapes can be segmented and made out of flat panels. The anisotropic structure thus produced is capable of reaching the desired shape thanks to stress redistribution due to bending and torsion. The latter are induced in the assembly phase by individually bending and mutually connecting the patches.

The strengths of these systems lie in the spiral geometry, which can produce bespoke panels by only modifying the geometrical parameters without changing the material. Moreover, having a spiral path rather than a linear path results in less bending stress for obtaining the same curvature.

Recently, a new project that aimed at consolidating the use of FlexMaps in advanced architectural design, automates the workflow that links shape design to digital fabrication. This workflow includes shape design, optimization, structural verification, 2D layout design and digital fabrication. The demonstrator of this method is shown in the photos and has been built at the School of Architecture (Faculty of Design, Architecture and Building, DAB) of the University of Technology Sydney. It has been entirely fabricated at the Advanced Fabrication Lab by machine milling 15 mm plywood sheets. This research project demonstrates how FlexMaps can be efficiently integrated into a real-scale architectural production process and adapted to the complexity of contemporary design.

Credits

The demonstrator has been entirely fabricated at the Advanced Fabrication Lab of the UTS School of Architecture. It has been assembled by 4-5 people in about 2 days, and exhibited  at The Space (DAB, UTS Building 6) from February 24, 2020 to March 06, 2020. Then, it has been disassembled and assembled again at the Ground Floor of FEIT (UTS, Building 11) where it is to date.

Research Products

Luigi Malomo, Jesús Pérez, Emmanuel Iarussi, Nico Pietroni, Eder Miguel, Paolo Cignoni, Bernd Bickel “FlexMaps: Computational Design of Flat Flexible Shells for Shaping 3D Objects” ACM Trans. on Graphics - Siggraph Asia 2018, Volume 37, Number 6, page 14 - nov 2018

http://vcg.isti.cnr.it/Publications/2018/MPIPMCB18/

Francesco Laccone, Luigi Malomo, Jesús Pérez, Nico Pietroni, Federico Ponchio, Bernd Bickel, Paolo Cignoni “FlexMaps Pavilion: a twisted arc made of mesostructured flat flexible panels” FORM and FORCE, IASS Symposium 2019+Structural Membranes 2019, page 498-504 - oct 2019

http://vcg.isti.cnr.it/Publications/2019/LMPPPBC19/

More info and photos on the FlexMaps Pavilion: 

http://vcg.isti.cnr.it/activities/pavilion/