Clay Extruding Barrel Vault

Aug 2022

Fabrication Robots The fabrication studio utilized two ABB robots with WASP clay extrusion tools (a1) at the Advanced Research & Innovation Lab (ARI) at the University of Pennsylvania Weitzman School of Design.

Simple Contour Printing The experiment begined with simple contouring approaches which are common in the field right now (b1, b2, b3). We also tested changing the Z-axis orientation of the extruding nozzle (b4) to create better curved wall finishing. The test was aborted due to the risk it brought to the robot (b5) and the little effect it added to the print.

Solid 3D Printing To produce alternative aesthetics, we explored transfering FDM (Fused Deposition Modeling) 3D printing tecniques to clay extrusion. With appropriate cap, infill and support (c1, c2, c3, c4), we were able to move forward from cylinder-like ceramics to real 3D printed ceramics. We also managed to improve our print quality throug minor adjustments (c5, c6). However, the limited amount of clay made us cancel this proposal.

Rigid Interlocking For better assemblage, rigid interlocking methods were tested (d1, d2). The inavoidable system errors suggested that ruled surface interlocking is a viable mechanism.

Fabrication Ruled surface interlocking utilizes the contour printing characteristic of 3D printing while positioning parts in self-locking, offering more tolerance throughout the system (e1). With brick units covering different rotation angles (A), the system combines multiple arcs to approach catenary lines (see left).

Site and Design After Philadelphia’s Richmond Generating Station ceased operation in 1985, it has been abandoned. Without working functions, it still demonstrates the unique aesthetic and cultural trends of that era for industrial architecture.

The design concept is to create a memorial space inside the giant turbine hall, a tomb for a past era. In today’s world where clean energy is widely used, we hope our design triggers thoughts over our industrial architectures and their energy consumption.

The composition of barrel vaults and the changing type and density of hollow bricks create a meandering effect of light and shadow.

The design features a series of corridors covering the second floor of the turbine hall and is connected to the surrounding machines and walls. The barrel vaults are inspired by the present cruciform ceiling, forming a double-roofed space.

ARCH 707 Advanced Architectural Design Fabrication Studio / University of Pennsylvannia

Co-produced with Ranran Zhang / Instructed by Na Wei