GlassCast is an ongoing research project into glass forming using reconfigurable molds

Glass is a ubiquitous part of the built environment today, but rarely is it seen in applications involving curvature. This is both a result of the complexities of working with such a sensitive material, and the high cost of tooling and the forming processes required to control its shape.  Contemporary design is moving towards a more performance based computational model, connecting generative algorithms with secondary and tertiary inputs such as environmental and structural performance as well as fabrication and material constraints. This project seeks to tie these complex influences into one cohesive process, from design to fabrication.

Central to the development of the process was the design and fabrication of a servo controlled reconfigurable glass slumping kiln. Based on the classic “pin mold” typology, the kiln allows the rapid reshaping of the mold surface, to allow the production o0f continuously variable components from a single tool. Coupled with the development of custom jig systems for robotic abrasive waterjet cutting, the system can produce uniquely trimmed, double curved components in standard float glass. Parallel to this trajectory has been the development of custom grasshopper components to aprovide the designer with instant feedback on the limitation of curvature and scale which the kiln can produce. The components then produce the output to the kiln for the positioning setup, which is driven through a custom motion controller.

The initial work culminated in a installation which ran from January to April at Liberty Lofts Annex, in Ann Arbor, MI.

Project Credits:

Lead: Wes McGee of Matter Design Studio and Catie Newell of Alibi Studio

with Aaron Willette, Lucy Olechowski, Brandon Clifford

Fabrication Team:

Grant Weaver, Simon Rolka, Patrick Ethen, Maciej Kaczynski, Etienne Turpin, Andrew Stern, Brian Muscat, Chuck Newell

Consultant:

Steve Karnowski

This work has been funded by:

Research Through Making Grant | Taubman College of Architecture and Urban Planning

and

Office of the Vice President of Research | University of Michigan

We feel strongly that great designs appear to be effortless.  Objects of desire that function, while maintaining a state of comfort.  Our design methodology translates proven and established classics into contemporary methods of making.  This translation serves to invert a new identity for a familiar strategy.

For this project, we tackled the twisted-stick coat rack as a typology.  Our first inclination was to melt and weld these sticks together.  Though impractical, it would have been possible to purchase a tree and carve this object out as a solid.  Instead we looked to 5-axis milling as an operation to ensure three individual sticks could be carved efficiently, shipped efficiently, and still align precisely with mechanical fasteners.  Clever spiraling fastener placement allows the single component to attach to itself, instead of requiring variation between the sticks.  In doing so, we were faced with the challenge of producing the moment in the design we are most fond of — the belly buttons.  These internalized nubs rhetorically call for the bolts.  The three sticks wrap around each other in such a way that the bolts align with the neighboring parts, making the assembly a simple task that requires no instruction manual.

We hope you can help Pongo find a great home.

Brandon Clifford and Wes McGee are to instruct the Oganic Fabrications Workshop at the University of Michigan Taubman College on Saturday and Sunday January 28–29, 2012.

This second installment in the workshop will build on work done in the first workshop, though participation in the first is not a per-requisite for attending.  The Organic Fabrications workshop is dedicated to advancing complex modeling and making of organic geometries.  We will understand the principles of surface curvature, as well as promote the control of these principles to resolve our geometries with constraints.  The workshop will then translate these principles into fabrication methods.  T-Splines for Rhino will serve as the platform for these operations.

If you are a member of the TCAUP community and would like to attend, please sign up here.  Space is limited.

We are pleased to announce that “The Malleable Manifesto no.1″ has been published by Plat Journal in issue 1.5.

We are pleased to introduce Coat Rack — our next furniture item.  It is currently in the prototyping phase and we look forward to sharing more documentation soon.

The workshop with Wes McGee [ matter design studio / Taub­mann Col­lege of Archi­tec­ture ] and Dave Pigram [ supermanouvre / university of technology sydney] explores the idea of funicular structures coupled with the robotic hotwire cutting process. Hotwire cutting is a highly effective and relatively novel approach to the production of volume and is highly effective in the production of volumetric elements of EPS foam. The workshop explores the potential of EPS formwork while revisiting the idea of half-timber structures. Part of the formwork will be come structural, part of it remains within the structure, part of the formwork will be disposed off / recycled.

The workshop is open to a limited number of external students at a reasonable fee of €150, including workshop materials.

Brandon Clifford and Wes McGee are to instruct the Oganic Fabrications Workshop at the University of Michigan Taubman College on Saturday October 29, 2011.

This workshop is dedicated to advancing complex modeling and making of organic geometries.  We will understand the principles of surface curvature, as well as promote the control of these principles to resolve our geometries with constraints.  The workshop will then translate these principles into fabrication methods.  T-Splines for Rhino will serve as the platform for these operations.

If you are a member of the TCAUP community and would like to attend, please sign up here.  Space is limited.

Our Ply Shelves will be on sale this Tuesday (September 20, 2011) on Fab.com.

We are proud to announce, Brandon has been selected as this years winner of the 2011 SOM Prize by the SOM Foundation and will recieve a funded travel fellowship.  He will use this opportunity to expand the current research in stereotomy.  To learn more click here.