Many Small Elements

Team member(s): Pier Paolo Rauco, Martina Caruso, Raul Winkelmann, Cheng Hen Chen, Fleur Francesca Varel, Aakriti Singh, Julia Sangalo and Soundouss Aboussekhra
Modified by Pier Paolo Rauco on May 7, 2024

Design References

Design

Simulations

Cladding Composition

The Sandwich Panel is a combination of a top 6mm Polycarbonate Sheet with Dry Insulation and Cork forming our inner layers and to finish it off with a 6mm thk Polycarbonate Sheet at the bottom.

For the inner insulation : egg cartons + Dry Fiber + Linear polycarbonate sheet to prevent air leakage

Fabrication Process

Using plywood as a base for dowels, which would serve as lateral support and boundary for the space designated for each wooden slat in the jig, a strategy was developed for drilling holes for dowels and bolts, and cutting according to the required sizes of the pieces needed for the wooden structure composition.

***Rotation strategy used to make the holes for Dowels and Bolts with the CNC Machine***

The first face to be crafted was called the “front”. After the necessary drilling and cutting, the wooden slats were rotated clockwise for drilling the second face. Then, the slats return to the “front” face and are rotated counterclockwise for finishing the piece.

***Jig dimensions to fit 26 Timber Beams***

The process optimized the time for drilling the pieces and taught us the need for coding the faces of the wooden slats, as well as coding identical slats, in order to identify them efficiently in the subsequent assembly process. Additionally, we established a tolerance of 1mm for the space designated for fitting the 35x35mm section wooden slats, which in many cases, due to wood variation, made fitting difficult, requiring the use of a hammer to press the piece into the jig. While a good tolerance can facilitate fitting, it should be approached with caution to ensure the piece fits snugly and does not move during the use of the CNC machine.