Developable^2
Developable^2: A Modular System for Building Lightweight Non-Developable Surfaces
Humphrey Yang. Advisor: Bart van Bueren
Building non-developable surfaces is difficult, especially in a large scale. With the introduction of Developable ^2, users can now build room-scaled, lightweight pavilions or installations with ease using cardboards. Each unit is parametrically modeled to generate fabrication files. This technique uses accessible tools and materials to promote accessibility for DIY makers.
Concept
The Idea of developable^2 is to design a system that can shape any surface using a repetitive element made out of corrugated cardboards. All elements, when unfolded, are identical and by altering few parameters will affect the shape of assembled surface.
Cardboard Unit
Mechanical Experiment
Several cardboard units were tested with a hydraulic press to measure their structural strength. The results indicate that the corrugation direction has critical impact on the structural integrity of the units.
Connector Length/Angle
Forming
Users can create a wide range of surface curvatures by modulating the length of the connectors. With Developable^2, users can create both developable (singly curved) and non-developable (doubly curved) surfaces.
Developable Surfaces (singly curved)
These surfaces bend on one direction and the units have a constant size and design, making it ideal for mass production.
Non-Developable Surfaces (doubly curved)
Doubly curved surfaces bend on both directions, distorting each module and making it difficult for mass-production. Units have to be customized with a CNC router due to irregular sizes.
Developable^2 Design Tool
The tool is packaged into a Component for the 3D software Rhinoceros and Grasshopper. Users can define the target surface shape as a CAD model along with some other parameters to modulate the reference size of each unit. The interface provides previews of the design to visualize the installation and instructions for assembly. The output is a file containing Splines (.dxf) for CNC cutting.
Application
With the help of my peers and our industrial sponsor Yuen Foong Yu, we design and build an in-scale installation in the department of architecture, NCKU. The design wraps the basement corridor with Developable^2 to functionalize the space.
