Documente Academic
Documente Profesional
Documente Cultură
PAR
Suisse
2010
Abstract.
and thus not only cover space, but also act as load bearing elements.
The variation of
light and shadow along the folded faces emphasizes the plasticity of space and envelope.
Folds not only create structural depth, but also perceptual deepness. Folds give rhythm
to space, and variations can be used to express a spatial sequence as well as to modify the
structural strength. Because of this we are convinced that a design method which rapidly
generates and modies folded plate structures is of great interest, and can form the basis
of a productive collaboration between architects and engineers.
In the last fteen years the timber industry has developed new, large size, timber
panels. Composition and dimensions of these panels and the possibility of milling them with
Computer Numerical Controlled machines shows great potential for folded plate structures.
An interdisciplinary team investigates architectural, structural and mathematical aspects of folded plate structures.
The main focus of the architectural portion is the form-nding process which is inspired
by Origami, the Japanese art of paper folding. Based on a simple technique, Origami gives
birth to an astonishing formal richness and variability. Complex geometries are generated
in an economic way and this research aims at transferring these principles to construction
with timber panels. In an intuitive approach, we investigate dierent folding patterns with
paper folding.
A great
variety of forms can be generated. This variability is attractive because it allows the engineer as well as the architect to react on project specic conditions by modifying dierent
parameters of the folded plate structure without distorting its expressive character.
Further on the possibilities of oseting the generated surface are investigated.
inuence of dierent parameters on the oset geometry is shown.
The
Finally a series of prototypes investigates the feasibility of folded plate structures generated with the proposed design method.
Keywords.
Rsum.
tures plisses en vue de construire ces structures avec des panneaux de bois massif contrecoll.
Par leurs qualits structurelles, spatiales et plastiques, les structures plisses intressent
la fois les architectes et les ingnieurs.
Une srie de plis rigidie une surface mince. Une surface mince plisse peut donc agir
la fois comme lment couvrant et comme lment porteur. Le jeu d'ombres et de lumire
le long des facettes plisses souligne la plasticit de l'espace et de l'enveloppe.
Les plis
ne crent pas uniquement une profondeur structurelle mais aussi une profondeur spatiale
et perceptive.
souligner des squences spatiales, mais aussi pour modier la rigidit structurelle. C'est
pourquoi nous sommes convaincus qu'une mthode de modlisation capable de gnrer et
de modier rapidement des structures plisses est d'un grand intrt pour une collaboration
productive entre architectes et ingnieurs.
Les quinze dernires annes, l'industrie du bois a dveloppe des nouveaux panneaux
de bois de grande taille: Les panneaux en bois massif contrecoll. La composition et les
dimensions de ces panneaux, ainsi que la possibilit de les dcouper avec des machines
contrle numrique les rendent trs attractives pour des structures plisses.
Une quipe interdisciplinaire explore les aspects architecturaux, structurels et mathmatiques des structures plisses.
L'objectif de la partie architecturale est la modlisation de structures plisses qui sont
inspires de l'Origami, l'art japonais du pliage de papier. Bas sur une technique simple,
l'Origami donne naissance une tonnante richesse et variabilit formelle. Des gomtries
complexes sont gnres de faon conomique, et cette recherche vise transposer ces
principes la construction avec des panneaux de bois. Lors d'une phase d'explorations intuitives, nous tudions dirents schmas de pliage de papier. Nous analysons la gomtrie
de modles choisis dans le but de les modliser avec un logiciel 3D.
Une mthode qui gnre des surfaces doublement plisses est dveloppe. Ces surfaces
sont dnies par deux lignes polygonales:
transversale.
section transversale et le prol d'ondulation peuvent tre adapts aux conditions spciques
d'un projet. Par exemple, l'amplitude des lments de bord du prol d'ondulation peut
tre augmente an de rigidier les bords de la structure plisse.
attrayante car elle permet l'ingnieur, ainsi qu' l'architecte de ragir des conditions
spciques d'un projet en modiant les dirents paramtres de la structure plisse sans
altrer son caractre expressif.
Nous examinons les possibilits de dcaler les surfaces modlises an de leur donner une paisseur. L'inuence de dirents paramtres sur la gomtrie de la surface de
dcalage est montre.
Une srie de prototypes explore la faisabilit des structures plisses gnres par la
mthode de modlisation.
Mots-cls.
Acknowledgments.
people, who shared my enthusiasm, encouraged me, and gave me critical advice.
Here, I would like to express my thanks and gratitude to them:
Professor Yves Weinand who gave me the opportunity to undertake this research and
whose condence in my work let me discover and develop a fascinating subject.
The members of the thesis jury, Dr. Olivier Baverel, Prof. Franz Graf, Prof. Pekka
Heikinnen, and Prof. Luca Ortelli, for their critical examination of the work.
The colleagues of the IBOIS laboratory for their multiple supports and critical advice.
In particular, Franois Demoures and Ivo Stotz for their precious proofreading, Johannes
Natterer, Franois Perrin and Ivo Stotz for their contribution to the building and testing
of prototypes.
Marie Duthilleul, Marie Marcotty and Cline Kobel for their contribution to the drawings of this work.
Peter De Witt for his English proofreading.
Olivier Morand and Nicolas Vaucher for their friendship.
Cosma and Flurin, for their sunshine and unconditional condence.
Anglique Horsten, who encouraged me to undertake this research, actively supported
me along the whole way, and to whom I dedicate this work.
Further I would like to thank the Federal Oce for the Environment FOEN, WOOD 21,
who nancially supported part of this research.
Contents
Abstract
Keywords
Rsum
Mots-cls
Acknowledgments
7
13
Foreword
15
Part 1. Introduction
17
0.1.
Introduction
Chapter 1.
18
Method
19
1.1.
Folding shapes
20
1.2.
Geometry of folds
21
1.3.
Construction of prototypes
21
Chapter 2.
2.1.
Motivation
23
Origami
23
2.1.1.
Japan
23
2.1.2.
Europe
24
2.1.3.
Origami worldwide
25
2.1.4.
2.2.
Origami techniques
26
27
2.2.1.
Concrete
27
2.2.2.
Fiber-reinforced composites
28
2.2.3.
Timber
29
2.3.
Timber-derived panels
31
2.3.1.
31
2.3.2.
33
2.3.3.
OSB-panels
34
2.4.
36
2.4.1.
Freedom of movement
36
2.4.2.
Tools
36
2.4.3.
37
Chapter 3.
39
10
CONTENTS
3.1.
Diamond pattern
42
3.2.
Herringbone pattern
44
3.3.
Diagonal pattern
46
3.4.
Discussion
48
49
Chapter 4.
51
4.1.
Simply-corrugated surfaces
Introduction
51
4.1.1.
52
4.1.2.
Simple corrugations
54
4.2.
Parallel folds
58
4.2.1.
Corrugation mid-line
59
4.2.2.
60
4.2.3.
Amplitude
61
4.2.4.
62
4.2.5.
62
4.3.
Oblique folds
63
4.3.1.
63
4.3.2.
64
4.4.
Discussion
Chapter 5.
Reverse fold
67
69
5.1.
Introduction
69
5.2.
70
5.3.
73
5.4.
Reection - disambiguation
77
5.5.
79
5.5.1.
79
5.5.2.
81
5.5.3.
97
5.5.4.
112
5.5.5.
Amplitude variation
120
5.6.
Discussion
Chapter 6.
121
123
6.1.
123
6.2.
130
6.2.1.
132
6.2.2.
134
6.3.
139
6.3.1.
139
6.3.2.
156
CONTENTS
6.4.
Discussion
Chapter 7.
Oset
11
182
185
7.1.
Introduction
185
7.2.
186
7.2.1.
Oset
186
7.2.2.
188
7.2.3.
190
7.3.
192
7.3.1.
192
7.3.2.
195
7.4.
Discussion
197
Part 3. Prototypes
199
Chapter 8.
201
Plywood Prototype 01
8.1.
Introduction
201
8.2.
Geometry
202
8.3.
Model
202
8.4.
Joints
202
8.5.
204
8.6.
Loading tests
206
8.7.
Structural design
207
8.8.
Discussion
209
Chapter 9.
Plywood Prototype 02
211
9.1.
Introduction
211
9.2.
Geometry
212
9.3.
214
9.4.
Discussion
216
Chapter 10.
219
10.1.
Introduction
219
10.2.
Fabrication
220
10.3.
Discussion
220
223
10.4.
Conclusions
224
10.5.
Outlook
226
Bibliography
229
Bibliography
229
Appendix
233
12
CONTENTS
Chapter 11.
235
Chapter 12.
261
12.1.
Introduction
261
12.2.
Form Generation
262
12.3.
264
12.3.1.
Structural design
264
12.3.2.
Oset
264
12.3.3.
Fabrication
266
12.3.4.
Construction
266
12.3.5.
Assembly
267
12.3.6.
Gable faades
267
12.4.
Discussion
270
Credits
272
Curriculum vitae
275
13
to Anglique
Foreword
Listen to its tune while crumpling it, feel its resistance, its sharpness, smooth it out
and feel its softness, trace a line, rubber it out, paint it with a soft brush, mark it with a
pen, cut it, tear it, caress it with a pencil .... paper always holds a particular attraction to
me.
Paper is the space of our projections. When we write, draw or paint, we project our
ideas, our imagination, our emotions, onto the paper. Paper is a medium: it reects our
projections.
This
inversion creates a gap between the gure and its representation which opens up space for
interpretation. The representation has its own reality [
BV91].
The projection of an
abstract pattern is folded into space. The space is in-between: in-between the projections
and their medium, in-between the folds. The projections become tangible.
This work is motivated by my fascination for the relationship between representation
of space and space itself. The work is hybrid: In-between drawing and space, in-between
geometry and architecture, in-between project and construction.
essenzialmente struttura,
intendendo la dizione
Mor52]
Finally, going beyond the investigation of the formative act of architecture, it seems
that everything reveals that architecture as a fact is
essentially structure,
intending the
word structure in the sense that it is used in a mathematical logic, that is, a complex of
relations [
BM02, Mor52]
15
Part 1
Introduction
0.1. Introduction
This research investigates new methods of designing folded plate structures that can
be built with cross-laminated timber panels.
Folded plate structures are attractive to both architects and engineers for their structural, spatial, and plastic qualities.
and thus not only cover space, but also act as load bearing elements.
The variation of
light and shadow along the folded faces emphasizes the plasticity of space and envelope.
Folds not only create structural depth, but also perceptual deepness. Folds give rhythm
to space, and variations can be used to express a spatial sequence as well as to modify the
structural strength. Because of this we are convinced that a design method which rapidly
generates and modies folded plate structures is of great interest, and can form the basis
of a productive collaboration between architects and engineers.
An interdisciplinary team investigates architectural, structural and mathematical aspects of folded plate structures.
The main focus of the architectural portion is the form-nding process which is inspired
by Origami, the Japanese art of paper folding. Based on a simple technique, Origami gives
birth to an astonishing formal richness and variability. Complex geometries are generated
in an economic way and this research aims at transferring these principles to construction
with timber panels.
This thesis is structured in three parts:
Part 1
Presents the working method, the considerations that motivated the research,
and the intuitive form-nding by paper folding.
Part 2
Presents a design method to generate folded plate geometries and discusses the
conditions of application of this method.
Part 3
An appendix presents examples of geometries, and a rst full-scale building, designed with
the proposed method.
CHAPTER 1
Method
We chose an investigation method close to the architectural design process. Starting
with a wide range research phase we are going to circumscribe the subject in a series
of loops until crystallizing a precise project.
talking about a linear process even though, for questions of clarity, it is related as such.
We propose to work with three dierent lines of investigation in order to understand the
formal, geometrical and physical aspects of folded plate structures based on origami (see
gure 1.0.1).
Folding
paper is used during a form nding process. Dierent types of folding patterns
are explored in order to discover interesting geometries for architectural and
structural applications.
Analyzing
the chosen geometries in order to understand their properties, with the goal of
proposing a geometric design method that then generates them in 3D modeling
software.
Building
Issues and results of each type of investigation enable the comprehension of the other
explorations. For example, questions that arise during the building of prototypes will give
new points of view to the geometrical analysis, which could reveal dierences between
shapes generated by paper folding and by the computerized modeling tool.
20
1. METHOD
project can not be established by pure deterministic reasoning. His conceptual tools are
hybrid, moving in-between the disciplines, unifying subjective perception and analytic
observation.
To be original and authentic, intuitive perception and understanding should precede the
analysis and be established without preconceptions. For this reason we propose to initiate
the research by an intuitive, hand's-on approach and only in a second phase examine the
folded geometries with analytical tools. The inherent disadvantage of such an approach
is to rediscover things that others discovered before.
original perception which is of rst importance for an architect: see with your own eyes,
touch with your own hands, and feel with your own body.
An architect's reasoning is
21
How to transpose the material thickness of the timber panels onto the existing
geometry ?
Which is the shape of the panel edges and what kind of connectors can be used
to join the panels ?
The last three issues need close collaboration with a civil engineer. This part of the research
doesn't claim to give denitive answers to these questions but to measure the problems
that will arise. It is a rst step in the direction of the realization of folded plate structures
with timber panels. Engineering research has to explore these questions. However we are
convinced that it is important to anchor this research in a constructive reality. To approach
the construction of prototypes in an intermediate scale will give positive feedback to the
other issues of the research and develop the feasibility of larger scale structures.
CHAPTER 2
Motivation
This research is motivated by four dierent considerations:
Origami
ture and space of a building. Folded plate structures are therefore attractive
to engineers and architects. By the creation of a design method which allows
integration architectural and structural aspects, we intend to foster the collaboration of both professions and thus contribute to high architectural quality.
Since the late nineties, the timber industry has produced large size
timber panels for the construction of massive timber walls. This research intends to reveal the potential of these panels for folded plate structures.
panels where each panel has a dierent geometry. This facilitates the construction of folded plate structures with irregular and changing geometries.
2.1. Origami
In nature the principle of folding is widely dispersed: a large number of plant leaves and
insect wings deploy and stabilize thin surfaces with the help of folds. Human folding probably began with fabric and paper, thin and exible materials humans fabricate themselves.
Folding seems simple and evident so that it is likely that it developed simultaneously in
dierent geographical locations.
2.1.1. Japan.
XII
II
and in the beginning it was mainly used for religious purposes and ritual acts. Buddhist
monks painted their prayers on paper. Immaculate white paper is like a universe at its
beginning, a primeval material; everything is possible and the creation can take any form.
In the Shinto religion, paper embodies the divine nature and folded paper materializes its
presence. Kami, the Japanese word for paper, has a homonym that signies the Shinto
divinity's. Their very diverse nature inuences all aspects of Japanese everyday life. Paper
becomes an important symbol, accompanying the dierent rituals of the Japanese.
23
24
2. MOTIVATION
Paper is also used for very sophisticated wrappings which are often considered more
precious than their content. On their war campaigns the Samurai took with them talismen
made of folded paper. The way they were folded indicated the social position of the owner.
Rules of folding and wrapping are complex and express the taste for sophistication of
Japanese society.
Until the
IXX
century paper was a luxury good which was reserved for the aristocracy.
Only industrial production made paper a democratic consumer item. But also in everyday
households paper is mainly used for rituals and folded as a talisman or folded into boxes
and envelopes to conserve precious goods.
The oldest publication about Origami,
Senbazura Orikata
lished in 1797. It is an instruction to fold a thousand cranes. The crane is a talisman and
folding a thousand cranes cures disease. A memorial in Hiroshima commemorates a young
girl suering from radiation. She was folding cranes in the hope of convalescing.
The art of ritual origami folding is transmitted from one generation to another. The
folding of the complex gures demands strong concentration and a successfully folded gure
procures satisfaction and relaxation. The success of Origami in Japanese society is based
on cultural aspects but also on the pleasure of play.
The term Origami was invented only in 1880:
paper [
Vas05].
2.1.2. Europe.
Ori
Kami
signies
niques. In the XII century the Moors imported paper folding to Spain [
Eng89].
As the
tessellated oors of their mosques and palaces the foldings were abstract and geometric. In
Spain there is still a strong tradition of paper folding and the Pajarita, a geometric gure
of a bird, recalls the inuence of the Moors.
Figure 2.1.1.
2.1. ORIGAMI
25
In the XVII century publications about the rules of conduct at table show various
illustrations of folded napkins (see gure 2.1.2).
Tre08].
pedagogical tools. He proposed to initiate the learning process of his pupils by stimulating
their curiosity with games and handcraft:
of geometry and harmony.
accurateness. The international success of the Kindergarten spread the folding exercises
worldwide. Even in Japan folding was discovered in a new form.
Between 1928 and 1933
Bauhaus.
As was
Froebel
Joseph Albers
Alb52].
He incited
his students to investigate dierent materials with their inherent constructive and formal
logic. Working methods and tools were reduced to the most simple applications. One of his
favorite materials for such exercise was paper. His students discovered various interesting
forms and folding techniques (see gure 2.1.3).
Aikira Yoshiwazawa
folding techniques and gures were developed. Mathematicians, engineers, architects, designers and biologists investigated Origami and its potential applications to other domains
SF00, SS01], new techniques to fold maps [Miu02], aluminum cans [INI 92], air bags [Cip01] and stents for
surgery[YK03].
and disciplines. They invented foldable solar sails for satellites [
Har57]
26
2. MOTIVATION
of folding techniques and a seemingly unlimited number of fold patterns. Basically, we can
distinguish three dierent kinds of origami.
2.1.4.1.
Classic Origami.
always two dimensional. They start from a square sheet of paper and are generated only
by folding, without scissors and glue. There is a selection of basic patterns which are used
as starting points for the dierent gures. Originally Origami was an art which sought to
draw the character of a gure by allusions using the least resources possible. The skill is
not to create a perfect replica of a natural model by complex folds, but rather to sketch
the suggestion of a gure. Over the past 50 years, the basic forms and techniques were
well developed and today very realistic gures are being folded.
2.1.4.2.
Modular Origami.
exclusively with geometric solids. Primarily polyhedrons are folded but also spatial lattice structures, or representations of molecules. The geometrical gures are composed of
individual building blocks, which are stuck together.
2.1.4.3.
Origami Tessellations.
The
process. Some tessellations remain two dimensional but others become three dimensional
and the folded surface gets a certain stiness. Again, the variety of shapes is very large.
Some of the basic patterns are particularly interesting in their spatial development and
therefore deserve our special attention.
For the design of folded plate structures from timber-derived panels only folding patterns which include both a spatial, as well as a load-bearing eect, shall be of interest.
Figure 2.1.3.
Josef Albers
FF99]
27
Although many of the spatial folds have evolved from traditional gurative origami, we
will focus in this work on the area of modular Origami and especially on tessellations.
underlines the plasticity of space and envelope, and folds create not only a structural but
also a perceptual deepness. Folds give rhythm to the space and variations can be used to
underline a spatial sequence but also to modify the structural strength.
A thin horizontal surface can cover a large span but will bend under its dead weight.
The folds give the surface the resistance to support loads. Each inclined face of the folded
surface acts as a beam and is horizontally supported by the adjoining face.
If the load
gets too heavy the folds will open up and the surface will bend. Therefore the edges of the
corrugated surface have to be reinforced by bulkheads, tie bars or the foundations in order
It is interesting to note that the development of folded plate structures is closely related
to new building materials. Their implementation requires new construction methods and
oers new structural possibilities.
2.2.1. Concrete.
dead weight and to make them very thin. To avoid the buckling of the shell, its inertia
a)
b)
c)
d)
Sie60]
28
2. MOTIVATION
a)
c)
b)
Congress Hall by
and
Breuer
Nervi [Jon62]
and
has to be augmented and this can be eectively done by a corrugation of the surface
[
Tor61].
The rst generation of folded plate structures has a simple, one directional
corrugation, following a given form and is composed of repetitive elements. The principle
bearing capacity of the structure is achieved by its general shape which conducts the loads
naturally to the ground. The corrugation of the surface allows reduction of the material
thickness and the weight of the structure.
eciency,
surface.
supported by inclined pillars (see gure 2.2.2 a)). The surface of the vault is structured
by a ne undulation with small amplitude which increases the impression of thinness and
fragility of the vault. The
same principle, but has a much larger span and proportionally the height of the vault is
lowered . The undulating surface is perforated by rectangular openings for natural lighting.
The prefabricated elements composing the vaults are almost dematerialized.
They are
Pier Luigi Nervi and Marcel Breuer (Unesco Congress Hall, Paris, 1953-57 and
St.Johns Abbey, Collegeville 1953-1961) illustrate the principle: corrugated surfaces with
projects of
plane faces are joined to form a rigid frame (see gure 2.2.2 b) and c)). Dimensions and
presence of the folds are emphasized and characterize the architectural expression of the
building.
Most of the folded plate concrete structures have a simple geometry based on parallel
or inversely oblique folds.
which are not realized[
terials like ber reinforced plastic, that systematic research on folded plate geometries
started.
Z.S. Makowski
Voi07]
(see gure
a)
b)
29
c)
ing structure by
Piano [Huy72]
2.2.3).
lands [
Huybers
Benjamin
and
He created a construction
system for composite materials based on the tetrahedron as basic structural unit.
deepens the study of anti-prismatic structures, initiated by
Huybers
Ouarmby
and
and
Makowsky, in or-
Sed75a, Sed75b].
In
new geometries. Inspired by the shelter for migrant farm workers in California [
Quarmby
Sedlak
HVR70],
Qua74].
The mobile shelter for a sulfur factory and the structure for a carpenter workshop by
Piano
are regular anti-prismatic structures built with a single base element: a diamond folded
The research with composites is strongly application orientated: basic knowledge for
construction is not obtained by theoretical and conceptual deduction, but by direct investigation on prototypes [
Voi07].
shapes the general building form. For economic reasons the buildings are composed of a
large number of identical, prefabricated elements.
folded plate structures but the diculty in producing large timber panels prevents their
construction with this material [
Sie60].
Lei04].
glue laminated timber, plywood or layers of diagonal planks which were glued and nailed
to form a plate. Most of the plates are composed of a framework planked on one or both
sides with the above mentioned materials. The span of the structures is
10 m
to
25 m
The geometries are very simple and either composed of parallel or concentric folds. The
student hostel
Anette Kahn
At the fold-edge the plates overlap and are glued together. The joint is reinforced by folded
Lei04].
steel plates which are nailed on the outside of the timber panels [
30
2. MOTIVATION
a)
b)
Figure 2.2.4. a) Anette Kahn Wohnheim [
Tannhausen [Jac05]
Lei04]
b)
rehearsal room of
After an experimental phase in the sixties, folded plate structures in timber are rare.
It is the development of new timber-derived products that revived interest in this structural principle. In 1998 the timber manufacturer
folded plate roof. The span is
work planked with the new
[
Kle98].
by
44 m
K1 Multiplan
2 24 m
designed
Regina Schineis
Binder
(2002) (see gure 2.2.4 b)). Walls and roof are corrugated surfaces.
The corrugation follows the form of the building and is not reversed at the building's edge.
Structurally it is a series of two hinged-frames with a V-shape. Structure, shape and interior cladding are formed by glue-laminated timber panels which makes the building very
Jac05].
economic [
Folded plate structures simultaneously dene space and structure, which puts them at
the interface of architectural and engineering interests. By their simplicity, they attract
a great fascination. To achieve this simplicity and integrate architectural, structural and
construction constraints, both professions have to work in close collaboration. The key to
this collaboration is the manipulation of the folded plate geometry. Even though knowledge
about folded plate geometries exists, their design is laborious and restricted to some specic
geometries.
It is the goal of this research to provide a tool for the generation of folded
31
CB97].
The goal was to be independent of the limited dimensions of grown timber and
to dispose of a homogeneous material whose physical and mechanical properties are not
aected by growth-related aws. Plywood panels are made of crossed veneer layers that
are glued together. One great advantage of plywood is its dimensional and deformation
stability: changing the grain orientation of the veneers from layer to layer by 90 prevents
tangential and radial swelling and shrinking. Plywood has been a great success and plates
were used in such very diverse areas as: housing construction, shipbuilding, aircraft, etc...
A wide variety of timber-derived products has been developed since then. All products
are based on the principle of breaking down and reassembling the raw material wood.
The degree of decomposition aects the quality of the product. The load-bearing capacity
decreases with the degree of decomposition and the homogeneity of the material increases.
The deformation stability depends to a large extent on the composition of the panels.
DN02]:
Solid wood
Veneered materials
Chip materials
Fiber materials
Composites materials
The production optimization, the development of various glues, as well as the development
of materials that meet specic needs, led to a very wide range of products.
Several timber-derived panels are large sized and suitable for structural applications.
They can be classied into three types:
Depending on
size and disposition of the planks we can distinguish three types of solid wood (see gure
2.3.1):
layered panels
cross-laminated timber panels
block board panels
2.3.1.1.
Layered panels.
The maximum
length of the plates is 5 to 6 m, which corresponds to the maximal length of a plank that
is not glue-joined. The width of the plates varies between 2 and 2.5 m and the thickness
from 15 to 75 mm. The thickness of the lamellas is between 6 and 49 mm. The lamellas
of the middle layer are generally thicker than those of the exterior layers.
deformations of the panels the layers are glued together crosswise.
To prevent
exterior layers have a grain orientation parallel to the long side of the panel. All lamellas
32
2. MOTIVATION
are glued to both, the wide and the narrow side. The strength and rigidity of the panels are
similar to that of sawn timber. A large number of manufacturers produce layered panels
[
Sch04].
2.3.1.2.
els are larger than those of layered-panels: Their maximum size is 24 m long, 4.8 m wide
and 0.5 m thickness (see gure 2.3.2). The number of cross-laminated layers is odd, so that
the planks of the two outer layers are parallel. Generally the dierent layers are glued, but
two manufacturers connect them with aluminum nails or wood dowels.
Most panels are made of side cuts (see gure 2.3.2). Because of their strong deformation
these planks, situated on the edge of the log are not estimated by the saw mill industry.
This disadvantage is not important in cross-laminated panels. Indeed the deformation of
the planks is blocked by the crosswise disposition of the glued layers. The use of side cuts
is even advantageous because the peripheral bers of the tree have better strength values
than those in the center.
block panel
BW07]
33
usually be observed. The layers are glued together on their whole surface, which leads to
a quasi-rigid compound [
Sch04, DN02].
There are wide variations in the dimensions of the manufactured plates (see gure 2.3.4).
For planning and execution, this is a diculty, because the products are not compatible
with each other and thus the nal design must be tailored to a particular product. The
maximum size of the panels depends on production and transport conditions. Some types
of plates can be manufactured slightly curved; thereby the thickness of the board must be
adjusted to the curvature radius. Normally, the exterior layer of the panel has industrial
quality, but it can be adapted to specic needs. Most manufacturers oer to execute the
outer board layers in a dierent species.
2.3.1.3.
Block panels.
Boards are glued together by means of a block press to a large cross-section (see gure
2.3.3). Adjacent boards are glued together on their small side. Thereafter, the laminated
block is split parallel to the pressing direction in arbitrarily thick plates.
These single
layered panels are planed and then glued crosswise to a multilayer panel.
Because the
boards are glued on all sides, Block panels have particularly good strength properties and
good windproofness [
DN02].
for use in structural engineering and were made of three millimeter thick peeled veneer.
After the drying and sorting, the veneers are layered and hot glued. The veneers overlap
at the joints. The overlapping joints of the dierent layers have to maintain a minimum
distance in order to minimize the strength reduction of the panel due to the interruption
of the layers. The width of the panels is due to production constraints. The panels can
sidecuts
maincuts
longitudinal layer
glued finger joint
transversal layer
leng
th of
the p
anel
+/- 1
6m (m
ax. 2
4 m)
f the
width o
panel
+/- 3m
(max.
4,8m)
Sch04]
34
2. MOTIVATION
DN02].
veneers are used for panels that are loaded in both directions of the surface[
2.3.3. OSB-panels.
which are directly deburred from round wood. The strands are parallel and perpendicular
to the long side of the panel.
entation and the density of the strands. Four grades are distinguished corresponding to
dierent applications. OSB panels of type 4 are high-load-bearing panels for use in humid
AG05].
environments [
barrier. Magnum Board and Leno Strand are made of several, glued layers of OSB type 4.
The joints of the panels overlap. The mechanical properties of multi-layered OSB panels
are less favorable than those of laminated veneer lumber or solid wood panels. But they
have a high density which makes them interesting for acoustic applications.
Large size timber panels create new opportunities for architectural and structural design. In a publicity for plywood
claimed:
CB97]
The goal of this research is to reveal the potential of new timber-derived products for folded
plate structures.
CB97]
35
BW07]
36
2. MOTIVATION
Freedom of movement
Cutting tools
Machine code and control software
The tool head moves transversely along the gantry and can
also move vertically. With a ve-axis machine rotational movements of the tool head are
possible. The range of movement of large gantry systems varies between 35 and 50m in
length (Y), 3.5 up to 5m in width (X) and 0.48 to 1.2 m in height (Z).
2.4.2. Tools.
Saw blades, Chain saws, drills, milling cutters or other tools can be
mounted on the tool head (see gure 2.4.2). An appropriate tool is chosen in function of
the geometry of the cut and the degree of nish. The machine can change a certain number
of tools automatically. Which tool can be connected and how many tools can be changed
automatically determines the scope of the machine. In function of the type of workpieces
to be milled, the carpenter equips his machine with specic sets of tools.
a)
b)
Kol03]
movement [
37
movement and speed of the machine. To program the machine with the code, movements,
type and speed of tools have to be determined in function of the geometry of the work piece.
These features are programmed in specic software which then translates the commands
into the machine code. To guarantee a correct data transmission from the design software
to the tool programming software, the geometry must be properly dened and the two
types of softwares must have compatible data formats.
Because of the relative complex geometry of traditional framework, carpenters have
been equipped with dierent kinds of CNC milling machines for a long time, and have
experience and knowledge in using them. To mill panels for folded plate structures a large
size gantry machine is needed.
machines. They produce and mill the panels, and directly deliver them to the construction
site where they are assembled.
The use of CNC milling machines allows manufacturers to produce work pieces with
complex geometries and without need of false work. A large number of pieces with dierent
geometry can be rapidly produced.
Hun05]
blade [
c) circular saw
CHAPTER 3
folding method
paper lies on a plane surface and is folded 180 to make the crease. Thereby the paper
always passes by a two dimensional, completely folded state. It can then be opened up to
form a three dimensional polyhedral surface. The folding method generally allows good
control of the three dimensional shape.
parallel or oblique folds that run through the whole length of the paper. When opened up,
these folds form a simply-corrugated surface with alternating mountain and valley folds
(see chapter 4).
When
opened again, the paper is marked by a pattern of creases. It can be folded into a three
dimensional form by assigning the right oreintation to each fold: mountain or valley fold.
The bending of a straight fold is one of the basic techniques of Origami and called
reverse fold [
Eng89]
inection point where the main fold is reversed from mountain to valley fold. The more
acute the angle between the side folds, the bigger the angle between the two edges of the
main fold (see chapter 5).
a)
b)
Figure 3.0.1.
40
drawing method
of shapes which cannot be completely folded into at, two dimensional gures.
To be
foldable, the vertices of a pattern have to consist of six or four edges. Typically we use the
drawing method to investigate variations of patterns discovered with the folding method.
It is also useful for all patterns which are not based on straight folds that run through the
whole length of the paper, like reticulated patterns or some type of radial patterns.
During our investigations we often combined both methods (see gure 3.0.2).
We nally decided to choose three patterns which we considered particularly interesting
for folded plate structures built with timber panels:
Diamond pattern
Herringbone pattern
Diagonal pattern
All of these patterns have been used in others contexts before. Particularly the students
of
Josef Albers
and those of
Frank Zeier
Figure 3.0.2.
41
42
a)
b)
mountain folds
valley folds
Figure 3.1.1. a) diamond pattern b) hexagonal pattern
Yoshimura pattern
that thin walled cylinders show this kind of buckling pattern under axial compression
[
HA05].
It is interesting to note that the buckled cylinders after a rst failure are strength-
ened by the buckling pattern. This property has been used to design cans with thin aluminum sheets based on the Yoshimura pattern [
be approximated by this pattern [
Miu70].
INI+ 92].
43
44
mountain folds
valley folds
Figure 3.2.1.
Herringbone pattern
Herringbone patterns have been used to design complex napkin foldings. Due to their
doubly zig-zag corrugation they extend in two directions when unfolding . This capacity
has been used to build solar sails for satellites that could be packed in compact way
Miu89].
Ori
Miura
after the researcher who built the solar sails and proposed other applications for the
Hob93]and Kling
shows that the folded pattern can be obtained by two corrugation lines [Kli05].
pattern.
Hoberman
45
46
We
decided to keep this pattern because we were puzzled by its close relationship to the two
other patterns.
mountain folds
valley folds
Figure 3.3.1. Diagonal pattern
Diagonal patterns can be observed in thin cylinders which are compressed with a
rotation and in some plant structures [
47
48
3.4. Discussion
We chose three patterns for further investigation for the following reasons:
The fact that the three dimensional shape of Diamond and Herringbone pattern
can be controlled by the folding method was decisive for their selection.
They
Finally, we were also attracted by the fact that these patterns exist in dierent
natural phenomenas like buckling [
HA05]
DF02]
or unfolding of leaves [
and
Part 2
CHAPTER 4
Simply-corrugated surfaces
4.1. Introduction
Take a paper, fold a rst crease that divides the paper in two parts, continue to halve
each part, deploy the creases and discover the folding. Start again, vary the size of each
crease, fold them oblique, deploy and discover a new form. Play with it ! (see gure 4.1.1).
Even though it seems very basic to design a simply-corrugated surface, the parameters
that dene such a surface are limited, the possibilities of varying the design are rich and
strongly characterize the nal design of folded plate geometries. This chapter will discuss
the following points:
First
Secondly
Thirdly
52
4. SIMPLY-CORRUGATED SURFACES
sent the Origami based folded plate structures we use the system of orthogonal projection.
The folded plate structure is placed in a system of orthogonal coordinates
x, y, z
and pro-
jected to three projection planes. The third angle projection is used and the three main
projection planes are as follows (see gure 4.1.2):
0
sux . For example the projection of a point
0
annotated a .
xy
with the
xy
is
a on
the frontal
yz
with the
yz
is
PAHK07]:
The projection of a line is a line. In the special case when a line is parallel to the
projection rays the projection of the line is a point.
ABkCD A0 B 0 kC 0 D0 .
A0 B 0
B0C 0
AB
BC
Parallel line segments of equal length in space are projected to parallel line segments with equal length in the projection plane.
53
Height
Height
4.1. INTRODUCTION
54
4. SIMPLY-CORRUGATED SURFACES
succession of parallel mountain and valley folds. The orientation of a fold denes whether
a fold is a mountain fold or a valley fold.
We denote mountain folds as convex and valley fold as concave folds. In a 3-dimensional
space with given coordinates
x, y
and
Reading from left to right, convex folds are marked with (-), since the rotation from one
face to another is a negative rotation (clockwise rotation). Concave folds are marked with
(+) since the rotation from one face to an other is positive (counter-clockwise rotation)
(see gure 4.1.3).
Take a rectangular strip of paper with creases parallel to one edge. For any kind of
such a gure there exist two boundary states of the paper (see gure 4.1.4):
xz
view
Completely folded
xy .
yz
the paper takes its minimum extension. Now all the creases are parallel
xz
xz
xy ,
yz
view
within a rectangle.
Partially folded
In between these two states the paper can take many dierent shapes.
yz
xy
corrugation prole
yz
of the
and
completely folded.
y
x
e n+1
en
en
e n+1
z
x
4.1. INTRODUCTION
a) Parallel folds
b) Oblique folds
unfolded
partially folded
completely folded
55
56
4. SIMPLY-CORRUGATED SURFACES
4.1.2.1.
tween the folding process and the orthogonal projection. Let us suppose that the folding
and unfolding is linear, along a vector perpendicular to the frontal projection plane
xz .
The folding vector is then parallel to the projection rays. If we observe the transition from
unfolded to completely folded, we nd out that during the folding the faces contract along
the
xy
xy
xy .
but because their position is more and more inclined, the frontal pro-
xy
of a partially
and a completely folded geometry, they are very similar: both projections could represent a partially, as well as a completely-folded geometry.
Normally a three-dimensional
object is projected onto a two-dimensional plane. If we invert this process and project the
two-dimensional drawing of the front view into the three-dimensional space, this is similar
to unfolding a paper with the dierence that in real unfolding, the dimension along the
vertical axis
prole that indicates how far we project/unfold the faces of the frontal view into 3D space.
We can now substitute the unfolding by the projection which has the advantage that the
1
when we bend straight creases by reverse folds, because the bending angles vary during
the unfolding of paper. It will allow us later to directly draw a folded geometry in space
by indicating its form in the frontal view and the deployment of the faces in the prole
view (corrugation prole). The three-dimensional geometry can be simplied and dened
by two, two-dimensional drawings. The system of projections we use to analyze the folds
becomes a tool to design them.
4.1. INTRODUCTION
57
a)
b)
58
4. SIMPLY-CORRUGATED SURFACES
To dene a series
of parallel folds, a corrugation prole can be extruded along a vector that indicates the
width of the folded geometry. We use the following parameters to that characterize the
corrugation prole (see gure 4.2.1):
Interval I
Width W
Orientation (+/-)
- +
- - +
Curvature
(Concave + / Convex -)
idt h
(w )
Amplitude (A)
ew
edg
Interval (I)
inclination angle ( )
59
is either straight, curved or a poly-line. The corrugation prole oscillates around the midline.
The way the corrugation oscillates around the mid-line inuences the inclination
and are
symmetric about the corrugation mid-line. With a straight mid-line (see gure 4.2.2 a))
the inclination angle
4.2.2 c) and d) show corrugations which oscillate with constant inclination angle
the mid-line. They appear as less regular because the edge width
around
get stronger the more the mid-line is inclined in reference to a horizontal line.
corrugation mid-line is not straight, it strongly inuences the total amplitude
Amax
If the
of the
corrugation.
W1
A1
I1
a)
5
3
W1
b)
A1
I6
I4
I5
I3
W5
c)
A max
I2
I1
W3
W1
A max
W4
W2
A1
I6
I5
I4
I3
I2
I1
d)
W4
W3
A max
W1
1
1
W2
I4
I3
I2
A1
I1
y
x
CM
60
4. SIMPLY-CORRUGATED SURFACES
uences the architectural expression of folded plate structures. If the most common order
is an alternation of convex and concave folds, some other orders are possible. The inclination angle of such proles cannot be constant. Figure 4.2.3 a) and b) show corrugation
proles with horizontal edges that imply a succession two folds with the same orientation.
This type of corrugation separates edges that have mainly structural functions, from edges
that mainly cover the space. The expression of the prole becomes more box-shaped (see
gure 4.2.3 b)). When two or more concave respectively convex folds succeed each other,
the inclination angles get very small and the corrugation prole loosens its sharpness and
becomes more curvilinear (see gure 4.2.3 c) and d)). If such rounded proles might be
interesting for architectonic expression they are probably less ecient in their structural
behavior.
W1
A1
W2
I1
a)
W1
A1
W2
I1
b)
W2
-
d)
W2
-
+
+
A1
I1
W1
W2
2
1
W2
c)
W1
W2
W1 W1
A1
z
I1
y
x
4.2.3. Amplitude.
61
rectly inuences the strength of the folded plate structure. Here we distinguish the amplitude
of each crease, which can be modied individually and thus reinforce the structure
Amax
uences the possibility of bending the corrugation (see section 6.3 and gure 4.2.4 c) and
d)).
When we change the amplitude but do not vary the interval, the strength of the
structure gets doubly inuenced. The structural depth diminishes, but also the inclination
angle of the corrugation edges diminishes, and therefore the faces have less bearing capacity (see 4.2.4 a) and b)). If we can use amplitude to locally reinforce a corrugation, for
example the border that is particularly weak because it is not supported by other folds,
variation of amplitude can also be used for architectural reasons. Alternating small and
big folds, accentuating parts of the corrugation, can introduce rhythm to the enveloped
space, underline exceptional parts, and modify the intensity of light and shadow.
W1
A1
I1
a)
W1
1
A1
1
I1
b)
1
3
W1
W2
W3
A max A 2
A3 A4
A1
A max
I1
c)
W1
W2
A2
d)
I1
y
x
62
4. SIMPLY-CORRUGATED SURFACES
A,
x.
inclination angle
and interval
are
for
a given amplitude. Each face should cover the largest interval possible and at the same
time guarantee good structural behavior. As the amplitude
A,
be used to reinforce parts of the structure: the bigger the inclination angle
can
the better
the structural behavior under vertical load (see gure 4.2.5 d)) . As structures are also
charged by horizontal loads, the inclination angle
at the edge of the structure, needs to be optimized for both solicitations. Dierences in
inclination can also be used to give an orientation to space and to direct light reection
(see gure 4.2.5 c)) .
limited to the maximal width of the panel type that varies for dierent manufacturers (see
gure 2.3.4).
W1
A1
I1
a)
W1
A1
1
I1
b)
W2
A1
W1
W2
d)
I1
I2
c)
A1
W1
I2
W1
I1
I1
y
x
63
. The parameters of the corrugation proles are the same as for parallel folds. We
We then draw a
second corrugation prole whose correspondent edges stay parallel to the rst prole, but
have dierent edge widths and intervals. By dening a distance between the two proles
and linking the corresponding vertices we can draw the poly-surface with oblique folds
(see gure 4.3.1).
With this method the control of the general shape is not very direct
The corrugation prole of non-parallel folds doesn't necessarily represent the dihedral angles between the
faces. The dihedral angle of two faces is situated in a plane normal to the crease edge. In oblique folds
the cross section representing the corrugation prole is not perpendicular to all fold edges.
a)
b)
y
x
f1
f2
f3
f10
e1 e2 e3
f1
f2
e10
f3
f10
e1 e2 e3
e10
y
Figure
4.3.1. Design
of
oblique
folds
with
two
corrugation
proles
64
4. SIMPLY-CORRUGATED SURFACES
placed in a chosen distance and sweep a straight line along the two curves. By dividing
the curves in an equal number of segments we can dene a series of strips on the surface
by linking the segments with the rulings (see gure 4.3.2 a)). Starting from this surface
we can proceed in two ways:
(1) We directly design a poly-surface by linking two opposite vertices of each strip by
a diagonal. The resulting poly-surface is very close to the ruled surface but has
the following disadvantages (see gure 4.3.2 b)) :
The order of alternating concave and convex folds is disturbed. In the zone
where the corrugation mid-lines have parallel tangents, and the inclination
angles are very at, two convex folds follow each other. This problem could
be answered by choosing the opposite diagonals starting from the point where
the mid-lines are parallel.
(2) We link the vertices of the rulings by an a zig-zag line (see gure 4.3.2 c)). These
diagonals will be the convex folds of our folded poly-surface.
We then oset
corrugation lines. We can design the poly-surface by linking the convex folds and
the corrugation lines with triangular faces (see gure 4.3.2 d)). If we imagine the
ruled surface to be elastic and span on a rigid grid formed by the zig-zag line
of convex folds, we simply push down the surface at their edges in between the
vertices of the zig-zag line to create the valley folds (see gure 4.3.2 c) and d)).
This method to design oblique folded poly-surfaces is very advantageous:
If we want to design a
a)
b)
z
y
x
c)
d)
e)
y
x developed
Figure 4.3.2. Design of oblique folds with a ruled surface
65
66
4. SIMPLY-CORRUGATED SURFACES
The method of drawing a poly-surface with oblique folds starting from a ruled surface
can be used when the corrugation mid-lines are oblique to each other in all points, for
example with a hyperbolic paraboloid which is generated with two straight lines oblique to
each other (see gure 4.3.3). The inclination angle
corresponds to the inclination of the two corrugation mid-lines. To increase the amplitude
at the edge of the poly-surface we simply elongate the rulings (see gure 4.3.3b)).
a)
b)
z
y
z
y
Figure 4.3.3. Design of oblique folds approaching a hyperbolic paraboloid
4.4. DISCUSSION
67
4.4. Discussion
Simply-corrugated surfaces are developable surfaces, composed of plane faces that form
a succession of convex and concave folds which do not intersect within the surface. They
are dened by their corrugation prole which is constant for parallel folds and varies for
oblique folds.
The mid-line and the order of convex and concave folds are the parameters of the
corrugation line that strongly shape the general and the local form of the corrugated
surface.
We propose to describe the general form as a ruled-surface where a straight line sweeps
along the corrugation mid-line. When the rulings are parallel they form a cylinder surface
which is single-curved. Cylinder surfaces can be used to shape parallel and oblique corrugated poly-surfaces. When the rulings change direction the ruled surface is doubly curved,
3
They
corrugation prole parameters, we can design the most important aspects of a folded plate
structure.
It would be interesting to examine the design of folded plate geometries composed of multiple patches of
ruled surfaces.
CHAPTER 5
Reverse fold
5.1. Introduction
The geometries we are interested in are all based on the reverse fold (see gure 5.1.1).
By using the reverse fold, straight folds can change their direction in space. Therefore the
reverse fold is our main tool which allows us to design the shape of folded plate structures.
This chapter is divided in three sections which describe the following points:
First
Secondly
Thirdly
We investigate the reverse fold in orthogonal projection. The properties of orthogonal projection allow us to simplify the design of three dimensional reverse
folds and reduce them to two dimensions.
prole.
xz :
the
cross section
70
5. REVERSE FOLD
These pa-
Eng89].
It is used to change
A straight
main crease m is bent by two side creases s which divide the initial faces oblique
to the main crease. Two faces of the crease stay in position, whereas the other two are
reversed about the side creases: They are reected about a line dened by the geometry
of the side folds (see gure 5.2).
angle .
The folding process of a two-dimensional reverse fold clearly explains its nature and
geometry. Figure 5.2.1 shows the folding process step by step:
a)
b)
c)
d)
e)
f)
g)
h)
is concave whereas
symmetric about the main crease m . The main crease m
+
a)
71
e)
F3
m
s
m
F1
F1
F2
F2
b)
f)
s
F2
F3
F4
c)
F1 F2
g)
F4
m
d)
F3
F4
ms +1
z
y
x
F3
F1
h)
s 2-
F3
m-
F2
F4
m+
s1+
F1
F1
s 2++
mF1
F2
72
5. REVERSE FOLD
F3
F4
and
a2
s.
The segment
r.
b2 a2
a3
and
b3
of the
of the face
F3
b2
r.
b1 b3 and the side fold edge b2 a2
m
. Its opposite angle b3 b2 b3 and the reection of the opposite angle
r
b2 bm
3 b3 are identical to
a2 b2 b1
= 2.
b1 bb
and
b2 br3
bending angle :
The size of the bending angle is inversely proportional to the bending of the
main crease.
This shows the strong relationship between the bending angle
= 0,
2 . The side fold is perpendicular to the main fold and all the faces superpose.
The developed reverse fold shows the angular symmetry of the side folds which is
characteristic for two dimensional reverse folds (see Figure 5.2.2b ).
r
a3
a2
b3
b2
m
a1
b1
= -2
b3
b3
r
a3
a) folded
a2
a3
b2
b3
a1
b1
b) deployed
Figure 5.2.2. Two-dimensional reverse fold
73
of the main crease changes with the variation of the inclination angle
of the
faces.
The reverse fold in 3-dimensional space is a reection about a plane. The bending of the
main crease creates a vertex and two side folds which divide the initial faces. The second
part of the faces are reected about a
reection plane R,
Kli97].
edges [
of the faces.
the faces is in direct relationship with the size of the side-fold angle
side-fold angle
and
of
The reverse fold can be considered as a particular case of a developable 4-degree vertex
as dened by Human [
Huf76].
curvature which implies spherical geometry. We propose to present some of the properties
of the reverse fold in solid geometry.
74
5. REVERSE FOLD
b1 b3
F1
and
is dened by the
dihedral angle
F2
F1
and
F2
b4
m bends
F1 , F2 , F3 , F4
m+ .
The
s+
2 run from the inection point
b4
a2 b4 br2 and
2 =
s
1
and
s
1,
m+
are:
1 =
br2 b4 c2 .
Let us study the relationship between the obverse and the reverse part of the main
c2 we project a
+
perpendicular line to the axis of the convex and to the concave main-crease m , m . The
r
angle a2 b2 c2 and a2 b2 c2 measure the dihedral angle of the main-crease and its inversion.
r
r
Because of the equal length of the segments a2 b2 = a2 b2 , b2 c2 = b2 c2 and the common edge
a2 c2 , the triangles a2 b2 c2 and a2 br2 c2 are congruent. Therefore, the dihedral angle of the
+
1:
convex main crease m is equal to the dihedral angle of the concave main-crease m
crease (see gure 5.3.2b)). From the end points of the side-folds
a2
and
a1 b1 c1 = a2 br2 c2
(5.3.1)
The triangles
a2 b4 b2
and
a2 b4 br2
b4 b2 d and b4 br2 d
b4 b2 = b4 br2 and b2 d = dbr2 and
b4 br2 d
segments
b4 a2
and
F3
and
F4
a2 b2 c2 = a2 br2 c2
are a reected
a2 b4 b2 = a2 b4 br2 and b4 b2 d =
about a plane R dened by the
,
b4 c2 .
Kli97
75
b1
mb3
2
1
F2
c1
F1
a1
a)
c3
a3
b1
m-
b4
F2
F1
b2
b3
s
2
1
F3
F4
c1
s 1-
a1
a2
d
c2
1
c3
a3
r
2
m+
z
r
b)
F3
y
x
F4
a3r
b3r
b4
a2
'
1
b'2
c)
d
Figure 5.3.2. Reverse fold
c r3
76
5. REVERSE FOLD
It
In order to be able to take into account asymmetric positions of the two faces, we
consider the inclination angle
main crease
and
F2
and
Inclination angles
inclination angles
F1
such that:
(1 + 2 ) = a1 b1 c1
1 and 2 are equal and we can be described
as follows (see gure 5.3.2b) and c)):
and
= 2
(5.3.2)
db2 r
)
b4 b2 r
(5.3.3)
= arctan(
(5.3.4)
b4 b2 r =
(5.3.5)
a2 b2 r
tan
Substituting 5.3.5 and 5.3.4 in 5.3.3 and substituting 5.3.3 in 5.3.2 gives the relationship
of the three angles:
(5.3.6)
= 2arctan(
sin a2 b2 r tan
) = 2arctan(sin tan)
a2 b2 r
The reverse fold has two limit positions: completely opened or completely closed. These
two positions correspond to the inclination angles
and
(5.3.8)
2 . The associated
77
Reection as a
about
line or a plane. The reected object is a reversed copy of the original. Therefore, reection
is an opposite congruent transformation. In 2-dimensional space, we reect objects
line and in 3-dimensional space
about
a line or
about
about
physical term
o
For example a light ray changes in direction by reection o
: A physical object in motion or a wave bounces
a
a
surface. In contrary to the mathematical reection, the object doesn't cross the reection
surface. We refer to physical reection as reection
o
a plane surface the incident angle of the light ray is equal to the reection angle.
o
The
incidence angle and the reection angle are measured with reference to the normal to the
surface.
The
straight crease is split by a surface and one half of the split surface is reected about the
splitting plane (see gure 5.4.2).
The
o
folds (see gure 5.4.3). In folding, this principle is only valid for straight creases that are
bent by a reverse fold.
(Reection about a line in 3D space is not an opposite congruent transformation and can also be obtained
by rotation of the object around the reection axis by the angle ).
a1
a2
a
m
1
a 2m
a 2r
a)
r1
a 1r
Figure 5.4.1. a) Reection
ar
ai
r1
b)
about
a plane b) Reection
o
a plane
78
5. REVERSE FOLD
As gure 5.4.2 and gure 5.4.3 show, the two kinds of reections are closely related in
folding geometries. To distinguish them we will always use the term reection
referring to mathematical reection and reection
about, when
b1
b1m '' a1m '' c1m ''
R''
c1r
R
a1r
a''1 c''1
b''1
a1
a i '' c i ''
n''a
n b''
b''r
b i ''
''
i
b
r
b
''
a
i
a
''
r
a
''
ar ''c r''
about
a plane
nc
b
b1
ci
nb
na
R''
ar
z
z
x
y
x
o
c1m
c1
a1m
b1
a plane
cr
79
xy ,
frontal plane
xz
yz .
The main crease is positioned either parallel or oblique to the frontal plane
The reection plane
xz .
xz.
This conguration enables generatation of the folded plate geometry by two poly-lines: the
corrugation prole and the cross section prole.
First
Secondly
perpendicular to
xz .
We investigate reverse folds with the main crease parallel to the frontal plane
xz .
We vary the parameters dening the corrugation prole, show their inuence
on the geometry of the reverse fold and the limits of the parameter variations.
Thirdly
We investigate reverse folds oblique to the projection plane and show the consequences of the oblique position to the geometry of the reverse fold.
Fourthly
Fifthly
R.
+
the main fold edges m and
80
5. REVERSE FOLD
The normal
plane
nR
xz
nR are perpendicular.
r
i
The line a1 a1 r is parallel to the reection plane R . The normal nR is perpendicular
i r
i r
to a1 a1 r and divides the line in two equal segments. The projection of a1 a1 r is parallel
and the projection of the normal
i
edges a and
ar .
The projection of parallel lines non-perpendicular to the projection plans are parallel lines.
The ratio of length of two segments of a line is preserved in the projection.
reflection plane R
R''
ar
a r ''
a i ''
nR''
ai
a
nR
r
1
z
y
a 1i
x frontal pla
a 1i
ne xz
a 1r
81
xz
a single crease is positioned with the axis of the main fold parallel to the frontal plane
xy .
R.
xz
A reection plane
R,
, splits the crease in two parts. The second part of the crease is reected about
Starting with a crease with congruent faces and congruent inclination angles
of the
faces, we then vary chosen parameters of the initial crease in order to show the consequences
for the geometry and the foldability of the reverse fold.
We examine four dierent congurations:
Case 1
The faces and the inclination of the faces are congruent (F1
= F2 , 1 =
2 , W1 = W2 , I1 = I2 , A1 = A2 ).
Case 2
F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 ).
The faces and the inclination angle are unequal,
(F1 6= F2 , 1 6= 2 , W1 6= W2 , I1 6= I2 , A1 = A2 )
Case 3
Case 4
is congruent (F1
6=
The edges of the faces are not parallel to the crease edge, the inclination angle
is congruent. (F1
= F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 , W, I
andA
vary).
5.5.2.1.
Case 1: reverse fold with congruent faces and congruent inclination angles .
Case 1 (F1 = F2 , 1 = 2 , W1 = W2 , I1 = I2 , A1 = A2 )
This basic conguration of the reverse fold corresponds to reverse folds made in paper
folding. Due to its symmetry about a vertical plane, formed by the main crease edges
it is completely foldable: The inclination angles
the side fold angle
m,
exterior angle bisector of the projected main fold edges. This allows us to draw a cross
section prole in the frontal plane
xz
surface. The corrugated surface can then be reected about planes dened by the exterior
angle bisectors of the cross section prole.
The
plane
yz
xz
and the
corrugation prole
in the prole
are sucient to dene the geometry of the reverse fold. The cross section prole
of the reverse fold and the medial length of the facets. The
cross section prole is the mid-line of the reverse fold edges which are parallel to it. In
the frontal plane
xz ,
the edges of the reverse fold reect o the exterior angle bisector
R00
dened by the cross section prole. The distance from the cross section prole to the face
edges is given by the corrugation prole and corresponds to half the amplitude
fold.
of the
82
5. REVERSE FOLD
F1
and
F2
The crease is parallel to the x axis and the rectangular faces are congruent and symmetric
b1 b3 .
A reection plane
reverse fold.
In the frontal plane
xz ,
and
The distance from the cross section prole and an edge of the reverse fold corresponds to
half the amplitude of the reverse fold. The frontal projection of the reection plane
the exterior angle bisector of the cross section prole
yz
a000
1,
b000
1,
R00
is
d1 d2 d3 .
c000
1 indicate the inclination angle of the faces
and
2 .
the points
The amplitude
of
the reverse fold corresponds to the vertical distance between the edges of the faces.
Each projection gives some specic information about the reverse fold:
The interval
In
parallel lines
Frontal plane xz :
The cross section prole is the main information of the frontal view. It
their interval
and
A.
of the faces,
m.
c r3'
c 2'
c 3'
F4'
b 3'
r
3
c3
c 1'
a3
F'2
F'4
b3
I2
b'
b 2'
r
3
a 2'
c1
F1
b1
F4 F4r
F3
y
x
a 1'
a'
F2
a1
b2
F'1
F3'
a 3'
F3
c2
F4
a2
b 1'
I1
F'3
83
a 3r
c 3r
r
3
y
x
R''
a 3''
a ''2
F''
3
F''
1 F''
2
d1
d2
b 2''
b 3''
a 1''' a '''
2
a 1''
b 1''
A/2
A/2
c 1''' c '''
2
A
1
b 1'''
2
r
r
F3 '' F4 ''
r
3
b ''
a 3r '''
z
y
c d2
c d3
F4
b d3
F4 '''
F3 '''
a 3r ''
d3
c 3r '''
b 3 '''
I1
I2
c d1
F2
b d2
b d1
1
F3
a d3
F1
a d2
a d1
y
x
developed
Figure 5.5.2. Reverse fold with congruent faces and congruent inclination angles
84
5. REVERSE FOLD
Within the following we illustrate how these two proles can be used to generate a
folded plate geometry step by step.
Simply-corrugated surface
a)
b)
xz .
Design of a generatrix
Amax
yz .
parallel to the
am
in the
axis originating in
am .
c)
xz
a)
z
x
z
x
c)
y
x
b)
am
Amax
y
x
z
y
y
x
a)
b)
c)
c
d
b
a
am
a)
z
y
x
a
z
b)
z
y
b
a
z
c)
85
z
x
z
y
y
x
86
5. REVERSE FOLD
a)
R1
abc
xz .
R1 .
Reection of the second part of the simply-corrugated surface about the plane
R.
c)
corresponding to the
geometry are parallel to the rst two segments of the cross section line.
R1
R1
a
z
a)
c
b
R1
R1
a
z
b)
c)
z
x
z
y
y
x
The steps a and b of gure 5.5.5 are repeated using a reection plane
by the exterior bisector of the angle
c)
87
xz
bcd
R2 dened
crease edges of the folded plate geometry are parallel to the according segments
of the cross section prole.
c
d
z
a)
R2
R2
z
z
y
c
b
d
z
b)
z
x
c)
R2
R2
z
y
y
x
88
5. REVERSE FOLD
5.5.2.2.
Case 2: reverse fold with non-congruent faces and congruent inclination angles.
Case 2 (F1 6= F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 )
The case we studied in section 5.5.2 is symmetric: in their original position the faces
and
F2
F1
are congruent and in a symmetric position about a vertical plane passing trough
The cross
and
A and interval I
Figure 5.5.7 is very similar to gure 5.5.2 . The main dierences are the following:
As a consequence of the modication of the corrugation line the faces
have dierent amplitudes
I.
F1
and
F2
projection planes:
Horizontal view xy the interval a01 b01 is smaller than the interval b01 c01
Frontal view xz the projected edges a001 a002 a003 and c001 c002 c003 do not superpose anymore.
are shifted and indicate the dierent amplitudes
indicates the maximal amplitude
Prole view yz
Amax
1 and 2
The distance
b001 c001
of the corrugation.
A of the faces.
They
and interval
of the faces.
and
are
identical too (see equation 5.3.6). This can be read in the horizontal view and in the view
of the deployed crease:
a02 b02 b01 = b01 b02 c02 and ad2 bd2 bd1 = bd1 bd2 cd2 .
c3
c r3'
c 2'
c 3'
c 1'
a3
F'2
F'4
F4'
b r3'
b 2'
c1
F2
a1
F1
b2
b1
I1
ar3'
a 3'
F'1
F3'
a 3'
a2
b 1'
F'3
R
c2
F4
F3
b3
I2
b 3'
89
y
x
a 1'
F4
F3
a 3r
c 3r
r
3
y
x
c ''2
c 3''
a 3'' F''
4
R''
c 1''
a ''2
F''
3
a 1''
F''
1
d1
d2
b 2''
b 3''
b 1''
A max
2
A max
2
a 1'''
c 1'''
A
max
1
b 1'''
2
r
F3 ''
r
3
b ''
d3
r
3
F3 '''
c 3r ''
a ''
a 3r '''
c d2
c d3
F4
I1
I2
c d1
F2
2
b d3
c 3'''
b 3'''
z
x
F4 '''
b d1
b d2
1
d
F3
a d3
F1
a d2
a d1
y
x
developed
Figure 5.5.7. Reverse fold with non-congruent faces and congruent incli-
nation angles
90
5. REVERSE FOLD
5.5.2.3.
Case 3 (F1 6= F2 , 1 6= 2 , W1 6= W2 , I1 6= I2 , A1 = A2 )
The parameter that is modied in this gure is the inclination angle
of face
F2 ,
their amplitude
of face
F1
of the faces. As
F1
and
F2 .
(see
stays constant.
This has no consequences for solid folded plate structures but it will inuence the way the
folded plate geometry can be oset (see chapter 7).
Folded plate geometries with asymmetric inclination angles cannot be used for deployable
structures.
angles
as
angles
as
Horizontal view xy
The interval
a01 b01
0 0 0
Also, the angle a2 b2 b1 is smaller than the angle
the deployed crease where
is unequal to
b01 c01
as in gure 5.5.7.
and
In gure 5.5.8
1 > 2
and
and
2 ,
the
1 < 2 .
c r3'
c 2'
c 3'
c 1'
F'2
F'4
F4'
c3
a3
I2
b r3'
b 2'
a2
ar3'
a 2'
c1
F2
a1
F1
b2
b1
F'1
F3'
a 3'
F3
b 1'
I1
F'3
c2 R
F4
b3
b 3'
91
y
x
a 1'
F4
F3
c 3r
b3
r
3
y
x
R''
a 3''
F''
3
F''
1
d1
d2
b 2''
b 3''
a 1'''
a 1''
a 2''
b 1''
A/2
A/2
c 1'''
A
1
b 1'''
2
r
F3 ''
r
3
b ''
a 3r '''
z
y
c d2
c d3
F4
c d1
F2
2
b d3
b d2
b d1
1
F3
a d3
F1
a d2
a d1
y
x
F3 '''
a 3r ''
d3
developed
F4 '''
c 3r '''
b 3 '''
I1
I2
92
5. REVERSE FOLD
The asymmetry of the face inclination is limited (see gure 5.5.9 and 5.5.10s). A series
of parallel creases, which are positioned parallel to the frontal plane
xz ,
can be bent by
reverse folds without intersection of the faces when the corrugation prole has the following
characteristics:
The inclination
2.
b1 b2
and
virtual model but not be folded with paper. In order to avoid the intersections of the faces
their inclination angle
has to be limited:
<
5
The normal nR is parallel to the frontal plane xz since the reection plane R is perpendicular to the
frontal plane xz by denition.
c3
c 1'''
M'''
a1'''
F4
a3
F3
1
93
c2
c1
a2
F2
b3
b1'''
a1
b2
F1
b1
r
F4'''
F3 '''
nR
c 3r '''
a3r '''
b3r '''
F4
F3
c 3r
b3
x
y
a 3r
c3
c 1'''
M'''
a1'''
F4
a3
F3
1
c2
c1
a2
F2
b3
b1'''
a1
b2
c 4r
F1
b1
r
F3 '''
F4 '''
c 3r '''
a3r '''
nR
b3t '''
F4
F3
b3
z
y
a 3r
c 3r
x
y
94
5. REVERSE FOLD
5.5.2.4.
Case 4: reverse fold with face edges oblique to the crease edge.
Case 4 (F1 = F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 , W, I
andA variate)
In this case we modify the geometry of the face edges: they become oblique to the main
A single crease with skew face edges and the crease edge parallel to the frontal plane
reects o a reection plane
side fold angles
xz
a parallel fold whose face edges were cut in a oblique way. However we will rarely use single
creases for folded plate structures. We show this example to underline the importance of
the position of the crease edge relative to the frontal plane
creases edges oblique to the frontal plane
xz .
xz .
Let us consider a crease formed by faces of changing width (see gure 5.5.11).
edge length of the corrugation prole varies: edge
The
The inclination angle of the segments is identical. The developed crease is a parallelogram
with the crease edge
bd1 bd3
b1 b3
ad1 ad3
and
cd1 cd3 .
xz . As before, the initial
F 4 are reected about it. If
F3
and
with parallel folds, crease and face edges were all parallel to the cross section prole, in this
conguration only the crease edge is parallel to it. The inclination angles of the face edges
relative to the reection plane
R vary and thus they reect dierently than the crease edge.
The three views and the view of the deployed crease show the following characteristics :
is parallel to the
0 0
the face edges a1 a2 are parallel to each other. The reected segments
b02 br3 0 are not parallel.
Frontal view xz :
a02 ar3 0
and
It shows most clearly the character of the gure. The crease edge reects
o the reection plane parallel to the cross section prole. The face edges have
individual incident and reection angles. As the geometry of the face edges varies
the amplitude of the reverse fold changes. The initial crease is placed such as the
cross section prole represents the mid-line of its maximal amplitude.
Prole view zy
The crease edge is parallel to the x axis, which shows together with the
horizontal view that the reected crease edge forms a plane parallel to the frontal
view. The reected face edges
Developed crease
parallel.
shows that, except the
position of the face edges, the gure is identical with a symmetric reverse fold (see
section 5.5.2).
95
c 1'
c 2'
I2
c3
a3
c 3'
F'4
F4' c r'
3
b 2'
b 3'
F'2
F3
b 1'
b r3'
r
a 1'
F'1
F3'
F'3
b3
F4
a2
I1
F3
a 3'
F4
r
3
b c
r
3
a'
c1
F2
F1
y
r
a 2'
c2
b2
b1
a1
r
3
a 3r
R''
a 3''
a''2
F''
4
c 3''
F''
3
F''
2
d2
F''
1
b 2''
b 3''
c 1'''
a '''
3
c 1''
c''2
A max
2
d1
a 1''
c '''
2
a '''
2
A max
2
b 1'''
b 1''
c '''
3
a 1'''
max
z
r
3
b '' c ''
r
3
F3 '''
F3 ''
F4 ''
d3
a 3r ''
a 3r '''
F4 '''
b 3 '''
c 3r '''
c d1
c d2
c d3
b
F2
F4
b d2
d
3
2
1
F1
b d1
a d1
F3
a d2
a d3
y
x
developed
Figure 5.5.11. Crease edge parallel and face edges oblique to the frontal
plane
xz
xz
97
folds. In this section we investigate main crease edges oblique to the frontal plane
First
xz .
we show the consequences arising out of the oblique position to the frontal plane
xz
oblique reverse folds can be generated by a cross section prole and a corrugation
prole.
Secondly we dene the limits of the rotation relative to the frontal plane xz .
Thirdly we investigate the geometry of multiple reverse folds with the main
oblique to the frontal plane
crease edge
xz .
We investigate a position of the main crease edge oblique to the frontal plane
xz
under the
xz , the cross section prole is identical, and the main crease is placed in a horizontal
plane xy . The main crease edge is rotated in the horizontal plane xy with a rotation angle
h . Hereby the bending angle of the projection of the rotated crease edge does not change
plane
The rotation of the crease edge relative to the frontal projection plane
xz
has as conse-
quences the asymmetric splitting of the initial crease. The same cross section prole as in
the preceding gures generates a distorted reverse fold. The side fold angles
and
are
aFor cross section prole edges that are not horizontal, the rotation plan of the crease edge is perpendicular
to the frontal plane and intersecting the corresponding cross section prole edge.
a3
b3
a 2 F3
b2
a1
F1
F4
F2
b1
r
F3
z
y
x
c3
c2
c1
F4
c 3r
b3
a 3r
z
h
xt
yt
98
5. REVERSE FOLD
The parameter we change in this case is the position of the initial crease relative to
the frontal plane
xz
b1 b3 ,
xz ,
projection plane
F1
R,
F2 ,
plane xy
and
with symmetric
from a position
h .
the initial faces are congruent and have the same inclination angle
b1 b3 .
Even though
This auxiliary prole view is normal to the axis of the initial crease and allows one to see
the corrugation prole in real size. The four views and the view of the deployed crease
show the following characteristics of the oblique reverse fold:
Horizontal view xy
b01 b03
h
angle . The reected crease edge
c02 cr3 0
and
a02 ar3 0
take
a further rotation. They are not superimposing with the initial part of the crease
as in the preceding gures. The length of the edges
Frontal view xz
are unequal.
The only
Developed crease
2
c02 cr3 0
d1 d2 d3 .
000 000
a000
2 b2 and b2 c2
000
000 000
a000
1 b1 and b1 c1 .
and
and
this view stays very close to the ones of the preceding cases.
00 00 r 00
alteration is the shift of the edges a1 a2 a3 ,
Prole view zy
a02 ar3 0
The angles
and
0000
b0000
1 b2
and
r 0000
b0000
2 b3 .
c'3
99
c r3'
r
b'3
F4'
b r3'
F4'
c'2
a3
F3'
a'3
F3'
b'2
b3
a 2 F3
ar3'
b2
a1
a'1
a 3r
y
x
a'2
b'1
c 3r
b3
F3
z
F1'
F4
b1
c'1
F2'
c1
F2
F1
c3
c2
F4
yt
xt
R''
c''3
a''3
F''3
F''1
d2
b''2
b''3
F''2
d2
F4 ''
b 3r ''
b 1'''
cr3'''
F4 '''
F3 '''
z
r
3
a ''
b 3'''
a 3r '''
c d3
c d2
a 1''''
c d1
A/2
d
F4
d
3
F2
2
d
2
c 1''''
A/2
b 1''''
d
1
F4 ''''
1
d
F3
F3 ''''
F1
a d3
a d2
y
developed
b 3''''
a d1
a 3r ''''
I1
z
x
b 3'''
b 2'''
r
c 3'''
F'''
4
F'''
3
F3 ''
d3
c '''
2
a 3'''
F'''
2
A/2
c 3r ''
c 1'''
a '''
2
F'''
1
A/2
b''1
a 1'''
c''1
a''1
a''2
F''4
I2
yt
cr3''''
100
5. REVERSE FOLD
The generation of folded plate geometries with oblique folds (see gure 5.5.14) is similar
to the process described in gures 5.5.3 to 5.5.6.
a)
xz
c)
about
am .
am
ab.
z
y
x
h
z
b)
b
a
z
c)
z
x
z
y
y
x
Figure 5.5.14. Folded plate geometry with initial creases oblique to the
projection plane 1
h .
a)
xy
101
The following steps are identical with those described in gures 5.5.5 and 5.5.6 with
the dierence that the main creases of the resulting geometry are not parallel to the
frontal projection plane but approximate a helical form (see gure 5.5.15). For a better
understanding of the helical form generated by folds oblique to the projection plane see
also section 6.1 and chapter 11, gures 11.0.3 and 11.0.4.
c
b
R1
R1
a
a)
c
b
d
z
b)
z
y
c)
R2
R2
z
y
y
x
Figure 5.5.15. Folded plate geometry with initial creases oblique to the
projection plane 2
102
5. REVERSE FOLD
To analyze the consequences of an oblique position of the crease edge, we propose to show
the rotation of the crease edge in a horizontal plane
position oblique to the frontal plane
xz
xy
h
rotated about a horizontal angle (see gure 5.5.16).
The rotation of the incident crease edge implies a rotation of
M,
incident and the reected crease edge. The rotation axis is the normal to the reection plane
nR
to the bending angle of the cross section prole. In reverse folds oblique to the frontal plane
xz
of the rotated
t
crease are unequal. The bending angle of the rotated crease grows proportionally to the
h
horizontal rotation of the initial crease edge.
zx.
b1 r2
reects
r
o the reection plane and becomes r2 b2 .
R
and parallel to the frontal plane xz . The intersection of the crease edge plane M
with R is g . The normal nR of R is the interior bisector of the bending angle .
c) The incident crease edge b1 r2 is now rotated in a horizontal plane xy . The
h
t
rotation angle is . The frontal projection xz of the rotated segment b1 r2 supert
imposes with the projection of the initial segment b1 r2 . The rotated segment b1 r2
5.5.16
that is perpendicular to
is the incident crease edge segment of the crease oblique to the projection plane.
5.5.16
and
v
fold and the vertical inclination angle of the crease edge plane M (see gure 5.5.16).
t
Therefore we project a perpendicular to the edge b1 r2 from the point b1 which denes the
t
t
point b3 . The points b1 , r2 , b3 , n1 dene a pyramid composed of four right angled triangles.
This allows us to dene the bending angle
103
R
g
r3
r1
r2
c1
r2
a1
b1
b1
a)
b)
b2r
c 2r
nR
b2r
a2r
gt
r2
r2
h
b1t
c)
b1
d)
b1t
nR
nR
b2tr
r
2
r5
r4
c 1t
r2
b1
r2
a1t
b1t
f)
b1t
2
e)
nR
nR
b2tr
y
x
a2tr
c 2tr
n1
xz
104
5. REVERSE FOLD
r2 bt3
r2 b1
(5.5.1)
cos(h ) =
(5.5.2)
r2 b1
cos( ) =
2
r2 n1
cos(
(5.5.3)
r2 bt3
=
= cos(h )cos( )
)=
2
r2 n1
r2 b1
2
t = 2 arccos(cos(h )cos( ))
2
(5.5.4)
The bending angle
t
maximal bending angle max is
h
max
is
2.
h .
This only considers the axis of the crease edge. But the crease is composed of facets.
With a horizontal rotation angle
h
max
and the face on both sides of the plane. Therefore they could not be reected about the
plane.
We call the angle between the fall line of the crease edge plane
the
(5.5.6)
b1 n1
tan( ) =
2
r2 b1
tan(v ) =
bt3 b1
sin(h )r2 b1
sin(h )
=
=
b1 n1
tan( 2 )r2 b1
tan( 2 )
v = arctan(
(5.5.8)
bt3 b1
r2 b1
(5.5.5)
(5.5.7)
sin(h )
)
tan( 2 )
1t
and
2t
side folds. As in gure 5.3.2 the relationship between the bending angle
the inclination
t
crease edge b1 r2 (see gure 5.5.17).
angles
vertex
r5 .
r
crease edge plane M . The point
to the
These
points dene a pyramid with a series of right angled triangles which allows to determine
the side fold angles
1t
and
2t
105
Part b) of gure 5.5.17 shows the oblique reverse fold in a plane perpendicular to its
incident segment
b1 r2 .
1t
and
2t
faces:
1t = 1 + v = 1 + arctan(
(5.5.9)
sin(h )
)
tan( 2 )
and
2t = 2 v = 2 arctan(
(5.5.10)
sin(h ) v
)
tan( 2 )
r7
r5
t
2
r6
t
1
t
2
t
1
r2
b4t
Figure 5.5.18. Angles in oblique reverse fold
Mt
nM
is
v .
and the
106
5. REVERSE FOLD
= arctan(
and
as follows:
(5.5.11)
stituting
1t
and
2t
tan(
2 )
)
sin
t
by (see equation 5.5.4) and
respectively
by
1t
and
2t
(see equations
5.5.9and5.5.10)
1t = arctan(
(5.5.12)
sin( )
sin(1 + arctan( tan(
))
)
2t = arctan(
(5.5.13)
sin( )
sin(2 arctan( tan(
))
)
5.5.3.1.
As the rotation of the initial crease edge has as consequence an asymmetry of the facets
M t . If the
M t , the reected faces F3t r and F4t r do
t
are on the same side of M the reverse
faces (see gure 5.5.19). The limit situation is dened by the crease edge plane
rotated faces
F1t
and
F2t
h
If the crease rotation is too important, the reverse fold intersects himself. The limit of
h
the rotation is rapidly attained with strong inclination angles and with small bending
angles
Part a) of gure 5.5.19 shows a self intersecting reverse fold in a projection plane
y t z normal to the incident crease edge segment bt1 r2 . It appears clearly that the vertical
v
t
t
t
inclination angle of M is too big and for that reason the facets F1 and F2 are on the
t
v
t
same side of the crease edge plane M . The vertical inclination angle of M should not
exceed the following value:
v < (
(5.5.14)
By substituting
1 )
2
t
crease edge b1 r2 should not exceed:
the incident
arctan(
sin(h )
sin(h )
)
<
(
1
(5.5.15)
M t ''''
c
t
1
1 ) tan( ))
2
2
''''
t
1
''''
gt
r5
F1t
''''
tr
F3 ''''
r4
c 1t
c 3t ''''
t
1
107
a1t
F2
c 3tr
r2
tr
F4 ''''
b1t
tr
tr
2
b2tr ''''
a
c 2tr ''''
F4
''''
tr
F3
nR
b2tr
yt
a)
c 2tr
b)
yt
a2tr
108
5. REVERSE FOLD
of the corrugation
prole edges inuence the maximal rotation of the incident crease edge. Figure 5.5.20 shows
the relationship of the three parameters: The horizontal axis reports the bending angle
h .
h
horizontal rotation angles which are situated on the right side of a curve
and
do not
lematic. Even though the reverse fold does not intersect itself, the faces get very close to
each other and could hardly be built with timber panels.
aWe remind that the bending angle is inversely proportional to the bending of the reverse fold.
90
=3
=10
=20
=30
=45
=85
=60
80
70
max
60
50
40
30
20
10
0
6
20
40
60
90
120
170
bending angle
5.5.3.2.
109
When a geometry is designed by multiple oblique reverse folds, the crease edges and the
corresponding faces continuously rotate relative to the frontal projection plane
xz .
To
understand these positions, we propose to analyze a series of four oblique reverse folds
with a constant bending angle
xz
and
e00
are parallel to the cross section prole. The other views show that the edges are not
in a plane but distorted and describe a helical movement (see section 6.1 and chapter 11,
gures 11.0.3 and 11.0.4).
Two adjoining crease edges form a crease edge plan
M.
a, b
and
v
dene two crease edge planes M . They are rotated about an angle 2 . Due to the reversion
of the creases, the crease edge planes are always in the same position relative to the faces
(see gure 5.5.22). Thus, in multiple oblique reverse folds the asymmetry induced by the
crease edge does not increase or diminish. The position of the crease edge planes relative
to the faces is dened by the horizontal rotation angle
bending angles
is appropriate it is sucient
max
of the corrugation prole: if
max > 2 the reverse fold will not intersect
v
itself for any horizontal rotation angle . Otherwise the horizontal rotation of the straight
inclination angle
d
c
e
b
z
y
C
D
d''
C
D
e''
z
x
c''
b''
B
A
a''
A
z
y
110
5. REVERSE FOLD
In multiple oblique reverse folds the crease edges form a helix. Two adjacent crease
edges dene a crease edge plane
the plane
Mbc ,
edge
b, c
and
and
M:
edge
dene the
dene two crease edge planes, one with each of their neighbor.
Figure 5.5.22 shows dierent sections perpendicular to one of the crease edges of gure
5.5.21. Column a) shows the section and the elevation of the faces. Column b) shows the
dihedral angle of the faces (the corrugation prole of the crease) and the position of the
corresponding crease edge planes. Column c) shows the position of the obverse and the
reverse part of the crease relative to their common crease edge plane
Section A A
M.
a.
v
plane Mab is rotated about the angle (see 5.5.8). Column c) shows the reection
of the corrugation prole about a line normal to the crease edge plane
Mab .
The
Section B B
B B.
The position of the corrugation prole and the crease edge plane
Mbc
A A, column c).
Mab
are
Mab
v
about the angle 2 . Column c) shows the reection of the corrugation prole
can be obtained by a counterclockwise rotation of the crease edge plane
C C
Mbc .
D D. The corrugation prole
2v at each reversion of the crease.
and
and the crease edge planes are rotated about the angle
The relative position between the corrugation prole and the crease edge plane remains
constant.
If the bending angles
crease edge planes
a)
b)
c)
M'ab
M'ab
AA
111
a
b
a'
c
d
BB
b'
M'bc
M'bc
M'ab
M'bc
CC
M'cd
M'cd
c'
y
x
DD
d'
M'de
M'cd
112
5. REVERSE FOLD
is
constraint. The limits are dierent for parallel folds than for oblique folds.
Parallel folds
(see gure 5.5.23 a)) A simply corrugated surface with parallel folds must
R,
R,
- the surface is
is limited as follows:
0<<
Oblique folds
(see gure 5.5.23 b)) The edges of simply-corrugated surfaces with oblique
xz
lines. We will only consider the general shape and simplify it to two intersecting
lines
and
b.
and
spread angle .
At
b.
i
The incident edge a must not be parallel to the reection plane
i
the angle between R and a must be greater than zero:
R.
Therefore
(
) >0
2
2
By simplication we can dene:
>
i
The incident edge a must not be parallel normal
nR .
Therefore
<
2
2
The bending angle
<<
Due to the spread of the main crease edges, oblique folds are more dicult to handle
than parallel folds. If parallel folds can be used with almost any cross section prole
the
form of cross section proles for non -arallel folds is restricted, especially for those with a
wide spread angle
a)
113
b)
R
ai
2
bi
ar
nR
nR
br
ar
bi
114
5. REVERSE FOLD
and
and
of equal
and divided in four equal segments linked by straight lines which form four non-planar
quadrangles. In order to obtain planar faces we connect two opposite ends of each quadrangle by a diagonal. We now have a developable poly-surface composed of non-parallel
folds which approximate a ruled surface .
A reection plane
R,
a3 b3
that connects
and
b,
and
b,
and per-
(see 5.5.24). It is evident that the reected surface intersects the initial surface.
nR
poly-surface generated by the two lines. The incident crease edge segments are situated on
both sides of the normal to the reection plane
nR
reected poly-surface is intersecting itself. If we analyze the crease line of the side folds
in the undeployed poly-surface we can see that the side fold angles
d d
segment a3 b3 , are
2 . Normally, the side-folds are a sequence of alternating concave and
convex folds. In this case side-folds next to the middle segments are neither convex nor
concave. This singularity in the sequence of side-folds is also an indication that the surface
cannot be physically folded and will intersect itself.
b
b'
a'
b'3
a'3
b3
a
R
b' r
115
a3
z y
R''
b''
b'' r
a''3
b''3
a'''
3
nR
a''
a'''
b'''
b'''
3
b'''r
z
y
+
d
3
+/-
a3d
+
+
z
x developed
generating lines
116
5. REVERSE FOLD
a3 b3 ,
the intersection of the poly-surface is moved away from the mid-edge. The reected
and the initial poly-surface intersect in a line instead of a surface, like in gure 5.5.24.
Again the incident crease edges are situated on the left and on the right side of the normal
to the reection plane
nR
and the reected edges cross each other. By isolating the faces
that intersect themselves and showing them in a axillary view, perpendicularly to the
corresponding crease edge, we can see that the crease edge plane
is situated outside
the angle dened by the corrugation prole (see section 5.5.3.1). The angle between the
normal of the reection plane
nR
the reversed fold intersects itself even though the rotation of the incident crease edge
is
weak (see gure 5.5.20). In the deployed surface, close to the intersection of the surface, the
sequence of side-folds shows two concave folds instead of alternating convex and concave
folds.
b
b'
a'
b'3
a'3
b3
a
R
b' r
117
a3
z y
R''
b''
a''
a''3
b''3
a'''
b'''
a'''
3
b'''
3
nR
z
b'' r
b'''r
z
y
a''''
d
b''''
b'''' r
a''''
3
+
-
b3d
+
+
z
x developed
a3d
b''''
3
M''''
z
y
generating lines
118
5. REVERSE FOLD
To avoid the intersection of the reected poly-surface with the initial poly-surface the
position of the reection plane
gure 11.0.11). The angle between every incident crease edge and the reection plane R
must be smaller than
of the normal
n00R
2 . When all incident crease edges are positioned on the same side
The side-folds in the deployed poly-surface show the normal succession of concave and
convex creases.
119
b
b'
a'
b'3
a'3
b' r
R''
a3
b''
a''
a'''
3
b'' r
b'''
3
nR
x
a'''
b'''
a''3
b''3
b3
b'''r
+
-
b3d
+
-
a3d
+
-
z
x developed
generating lines
120
5. REVERSE FOLD
Bending the crease by reverse folds modies the amplitude in the reecting zone (see gure
5.5.27). The amplitude of the corrugated surface varies locally. The strongest modication
is perpendicular to the reection plane
section prole edges
and
b:
Amod = kA
1
2 sin( 2 )
k=
For small
60
k = 0, 5.
bending angles the amplitude increases in the reecting zone . With a bending angle of
the amplitude stays constant. If
> 60
For Folded plate structures we will mainly use bending angles between 90 and 150 which
signies that the amplitude is diminished by a factor
k = 0, 7
0, 5.
to
The diminished amplitude is balanced by the fact that in the reecting zone the number
of folds is increased.
7
The size of the bending angle is inverse to the bending of the fold.
mab
f2
iab
e2
f1
e3
A
2
A mod
b
ief
f3
e1
and factor
factor k (-)
2
1.93
1.00
0.71
0.58
0.52
0.5
0
0
30
60
90
angle
120
150
180
()
and factor
5.6. DISCUSSION
121
5.6. Discussion
The reverse fold is a reection of a straight crease about a plane. It can be generated
by two lines:
prole.
The cross section prole and the corrugation prole are sucient to dene the geometry
of folded plate structures.
geometries of asymmetric and oblique reverse fold cannot be obtained by the classic method
of paper folding where the crease has to be completely closed. The method is limited to
the bending of straight creases. Other types of four edge vertices, such as the rabbit ear
fold, cannot be generated by this method.
The conditions that limit the reverse fold have been dened. Two pairs of parameters
dene the nature of the reverse fold:
Symmetry - asymmetry
M.
If the faces
folded. Even though the aim of the present research is the construction of solid
structures, the distinction between symmetric and asymmetric structures might
be useful for deployable structures.
The asymmetry of a corrugation prole is limited: the inclination angle
of
its edges must be smaller than . Otherwise the faces of the reverse fold intersect
2
themselves.
Parallel - oblique
xz .
xz ,
If
are symmetric
plane
inuences
xz
xz .
xz ,
become
asymmetric and the reversed fold cannot be completely closed. A single oblique
CHAPTER 6
First
Secondly
Thirdly
We describe the limit states of the two main patterns and how they modify,
vertex and pattern type.
Sed75a].
The macro-form describes the general form of a folded plate geometry. The
124
xz .
le. There exists great freedom for the design of the cross section prole. Its shape can
be adapted in order to respond to architectural, structural, functional and constructive
constraints. For example the cross section prole can be designed such that vertical loads
are directly transmitted to the ground. Its shape can also be adapted to a spatial prole
required for a given program. Further the slope of a roof can be controlled by the cross section prole in order to drain the rain water. The cross section prole strongly characterizes
the form and space of the folded plate structure.
Shape of the corrugation mid-line The shape of the corrugation mid-line denes whether
the macro-form is a straight cylinder surface or whether this cylinder surface is locally
deformed. If the corrugation prole mid-line is a horizontal straight line, the macro-form
1
is a cylinder surface
surfaces whose longitudinal section is invariable. This restricts the formal possibilities of
folded plate geometries.
In principle, all macro-forms of the proposed geometries are approximations of cylinder
surfaces. But, there exists a certain freedom of variation around the straight cylindrical
form.
If the corrugation mid-line is curved, a poly-line, or sloped, the macro-form varies (see
gure 6.1.1 b-d)). The corrugation mid-line can take dierent forms but has to progress
forward in every point, otherwise the reected surface creates self intersections (see section
5.5.2.3).
A cylinder surface is dened by a prole which is extruded in some direction by parallel extrusion
[PAHK07].
125
xz
Simply-
corrugated surface oblique to the frontal plane, the bent surface has an helical shape. All
xz .
y axis the variations of the macro-form
types of corrugation mid-lines can be used for an extrusion oblique to the frontal plane
Due to the helical extension of the surface along the
becomes less explicit.
126
Figure 6.1.1 shows how the shape of the corrugation mid line and the position relative
to the frontal plane
xz
inuence the macro-form. The cross section prole is the same for
xz.
shows the macro-form when the initial surface is oblique to the frontal
xz .
Within the following we briey comment the gures of the second column.
6.1.1 a) The corrugation mid-line is straight and horizontal. The macro-form is a hexagonal prism.
6.1.1 b) The corrugation mid-line is a slightly sloping straight line. Basically it is a single
inclined face that is reected about the reection planes dened by the hexagonal cross section prole.
top .
6.1.1 c) The corrugation mid-line is curved.
evolves along the
axis.
that one can generate curved creases. Not only, the corrugation mid line but also
the corrugation prole could be curved. The generated surfaces are developable as
those which are composed of straight creases (see appendix gures 11.0.9, 11.0.14,
11.0.16). This opens new perspectives for applications with other materials than
cross-laminated timber panels.
6.1.1 d) The corrugation mid-line is a poly-line composed of two edges. The macro-form is
constituted by six reverse folds. It demonstrates that the dierence between the
generation of a macro-form and the bending of a straight creases is just a matter
of scale.
The macro-form has a strong resemblance to a triangular anti-prism. It is interesting to note that most of
the folded plate geometries proposed for structural applications are based on anti-prisms [Sed75a, KR78,
Huy99, Fro78].
(a)
z y
z
(b)
z y
z
(c)
z y
z
(d)
z y
z
127
128
(a)
z y
z
(b)
z y
z
(c)
z y
z
(d)
z y
z
of gure 6.1.1
129
Folded plate geometries corresponding to the macro-forms of gure 6.1.1 are shown in
gure 6.1.2. The corrugation mid-line is replaced by a corrugation prole. The contrast
between the form generated with a curved (see gure 6.1.2c) and polygonal (see gure
6.1.2d) corrugation mid-line is lessened by the creases.
Macro-forms with altering cross sections along their longitudinal axis are interesting
to create spaces with varying width and height. This is most eective with simple cross
section proles composed of only a few edges. Figure 6.1.1b) shows that a compression in
one direction always results in a decompression in the opposite direction. A short edge of
the cross section line is next to two long edges and alters to a long edge next to two short
edges. The slope of two adjoining faces is inverted. This is eective as long as the variation
of an element is signicant relative to the scale of the macro-form. Shapes generated by
cross section proles with many edges allow only small variations of the macro-form that
become insignicant. This eect is reinforced when the macro-form gets corrugated. The
alternation of concave and convex creases makes it dicult to read a clear reference surface
and therefore blurs small variations of the macro-form.
The macro-form of the proposed folded plate geometries is essentially a cylinder surface
which is simply-curved and has a strong orientation along the longitudinal axis.
shape is mainly given by the cross section prole.
The
The amplitude of
these variations is limited. They are particularly interesting for cross section proles with
few edges (see appendix, gures 11.0.1, 11.0.9, 11.0.10, 11.0.12, 12.2.1). The macro-form
can get a helical shape by using a corrugation prole extruded obliquely to the projection
plane.
The use of macro-forms is an ecient way to visualize the general shape of a folded plate
geometry without modeling the details of the corrugation (see chapter 9, gure 9.2.1 and
appendix, gure 12.2.1).
130
Their pattern is
corrugation prole
to the main-folds.
The unfolded pattern of the main corrugation is composed of parallel or slightly oblique
lines. It is very similar for all doubly-corrugated surfaces and thus not very character giving.
The secondary corrugation imprints a specic character to the main-fold pattern. The sidefolds reveal the shape of the main corrugation. By cutting across a series of straight folds
and reecting them, the side-folds design a skewed shape of the corrugation prole (see
gure 6.2.1).
As for the corrugation prole, the cross section prole is a poly-line with convex and
concave vertices. The order of convex and concave vertices characterizes the cross section
prole.
Main folds
y
x Developed crease pattern
z
y
Side folds
z
x
131
132
the bending of straight main-fold. Side-folds are formed in the reection plane
R.
Side-
folds and main-folds form a 4-degree vertex with one concave and three convex folds or the
inverse, three concave and one convex fold [
Huf76].
that the orientation of the main-fold is inverted: it always changes from concave to convex
or vice versa. Thus both side-folds are either concave or convex. Their orientation depends
on the change of direction of the main-fold, represented by the cross section line.
B ).
and
The edge
en+1
convex cross section prole vertex. The resulting side-folds are convex folds independently
of the main-fold orientation.
and
en+1
is
D).
The side-fold edges form an arrow shape. The arrow direction depends on the mainfold orientation.
The rst
main-fold edge of gure 6.2.2 A is convex and the side-fold arrow points to the left. The
direction of the arrow is inverted if the rst main-fold edge is concave (+) (see gure
6.2.2
B ).
Figures 6.2.2
and
orientations of the rst main-fold edge and the side-folds are equal, the arrow points to
the left:
m , s and m+ , s+ = <
m , s+ and m+ , s = >
In the present example the four polyhedral surfaces are congruent and can be trans-
As for the
corrugation prole, we dene that in a cross section prole, the edges are denoted from
the left to right.
en
to
en+1
corresponding side-folds are convex (-). The side-folds are concave (+) if the rotation from
en
to
en+1
corrugation prole determines the orientation of the main-folds. The cross section
prole determines the orientation of the side-folds. Positive rotation of the cross section
The
edges results in concave side-folds, negative rotation in convex side-folds. The direction of
the arrow formed by the side-folds depends on the orientation of the main-fold.
133
nR
y
x
nR
en+1
+
nR
+
en
en
z
x
A'', (B'')
nR
C'', (D'')
en+1
s+
sms-
Ad
m-
m+
s+
Dd
s+
sm-
m+
m+
m-
m+
y
x
developed
Bd
s-
s+
134
corrugated surfaces are determined by their main-fold orientation and their side-fold orientation.
concave (+) and convex (-) folds. Such main corrugations correspond to the patterns of
paper folding and present characteristic qualities which can be extended to patterns based
on other main corrugations.
Two types of cross section proles which two basic patterns:
All
side-folds are convex. Their arrow direction alternates due to the alternating orientation
of the main-fold. The resulting pattern is composed of quadrilaterals. They are trapezoids
except for main corrugations with oblique folds, where the parallel sides of the trapezoids
are skewed. This basic form is copied by rotation along the
main-fold . Hexagonal pattern, Diamond pattern and, within certain restrictions, diagonal
pattern, presented in chapter 3, are based on convex polygonal cross section lines (see
appendix gures 11.0.1, 11.0.3, 11.0.4, 11.0.5, 11.0.6, 11.0.9, 11.0.10, 11.0.11, 11.0.12). To
create these dierent patterns the geometry of the basic quadrilateral has to be modied
(see section 6.3). Note that all convex folds are on one side of the cross section prole and
all concave folds on the opposite side.
The orientation of the vertices could also be constantly concave but for covering spaces with folded plate
structures we will mainly use cross section proles with convex orientation.
135
x
-
+
-
z
x
y
x
developed
Figure 6.2.3. Convex polygonal cross section prole
136
cross section prole alternates from convex to concave and so do the side-fold orientations
(see gure 6.2.4). In contrast to this, the arrow direction of the side-folds does not change.
Again, the pattern is composed of quadrilaterals which are trapezoids. The position of the
main-fold edges is shifted so that the side-folds edges are inclined in the same direction.
This basic form is copied by rotation about the
The herringbone pattern is based on a zig-zag polygonal cross section prole (see appendix
gures 11.0.6, 11.0.7, 11.0.13, 11.0.14, 11.0.15). Variations of this pattern and constraints
are discussed in section 6.3.
Again all convex folds are on one side of the cross section
137
x
-
y
x
developed
Figure 6.2.4. Zig-zag polygonal cross section prole
138
proles are the two most typical cross section proles. The rst one is based on side-folds
with alternating arrow directions (< >), and the second one on side-folds with unchanging
arrow direction (< <). Dierent folding patterns can be created by combinations of these
two basic types (see gure 6.2.5 and appendix, gures 11.0.2, 11.0.17, 11.0.18).
Each
pattern is characterized by a cross section prole with a specic series of concave and
convex vertex orientations. The constraints for each of these patterns can be derived from
the constraints of the two main cross section proles described in section 6.3.
+
-
+
-
139
correspond a maximum amplitude which the amplitude of the corrugation prole should
not exceed and that will limit the eective depth of the folded plate structure. It is therefore
important to know on which parameters the maximum amplitude depends. Furthermore,
it is useful to control the design of a cross section prole in order to respect a chosen
amplitude of the corrugation prole.
6.3.1.1.
edges
Maximum amplitude.
Let us consider a cross section prole composed of fourThe exterior angle bisector of two edges can be designed
is the mid-line of the corrugated surface, and reect the surface o the reection
Rab
A,
and
f,
R bc
R ab
a
z
x
Figure 6.3.1. Construction of the cross section prole
R cd
140
composed of alternating long and short edges parallel to the cross section prole.
For
given cross section prole is reached when a main-fold edge is reduced to a point.
Figure 6.3.2 a) and b) show the same cross section prole. The corrugation amplitude
is increased in gure b). The vertices
Rbc until they collide at the intersection of the angle bisectors. The maximum amplitude
Amax of the cross section prole corresponds to twice the distance between the cross section
prole and the intersection of the external angle bisectors. In an arbitrary cross section
prole, as in gure 6.3.2, this distance varies for each edge of the cross section prole. It
is then the shortest distance between a cross section prole edge and the corresponding
external angle bisector intersection, which determines the maximum amplitude
e3
e2
a)
R ab
R bc
Amax .
f3
f4
R cd
e4
f2
d
a
f1
e5
A
2 A
2
f5
e1
R bc
e2 e3
f3
f4
b)
R ab
A max
c
R cd
e4
f2
f1
A
2
z
e1
f5
e5
A
2
x
Figure 6.3.2. Maximum amplitude for a given convex cross section prole
6.3.1.2.
141
the valence of the vertices and the pattern of the folded plate geometry. Figure 6.3.3 shows
the developed patterns and axonometries of gure 6.3.2.
Normal amplitude
edges as well as of a convex and a concave main-fold edge. The pattern is composed of
quadrangles. The convex creases design an irregular hexagonal pattern.
Maximum amplitude
quadrangles. The second row of the pattern is composed of triangles: two four-edge vertices
with opposite arrow directions touch each other and form a six-edge vertex composed by
four convex side-folds and two concave main-folds. The convex side folds form a kite .
If the maximum amplitude is reached, the valence of the vertices changes: at the exterior angle bisectors intersection which determines the maximum amplitude, two four-edge
vertices unify into a six-edge vertex. The corresponding side crease pattern changes from
hexagon to kite form.
a)
x
y developed
y
x
b)
142
6.3.1.3.
bisectors
In-circle.
Rab
and
Rbc
ob
a, b
and
ob
b:
Amax b = 2 bob
The extension of edge
and
Iabc
a, b and c.
b.
, the unique circle which is tangent to all three sides of the triangle
abc
ob
abc5.
I
Amax = 2rmin
where
I
rmin
Vertex conguration and pattern design of convex polygonal cross section proles can be
controlled by the in-circle radius.
will have six-edges for a main corrugation with constant amplitude corresponding to twice
the in-circle radius. The pattern will be composed of kites or rhombuses (see appendix,
gures, 11.0.3, 11.0.4, 11.0.5). The in-circle radius is also useful to guarantee a minimal
amplitude
Amin
for every inner cross section prole edge (see chapter 9, gure 9.2.2).
With convex polygonal cross section proles the in-circle is only tangent to one of the edges of the cross
section prole and tangent to the extension of the two adjacent edges. We therefore name the in-circle
with the sign corresponding to the cross section prole edge tangent to it. For example in the present case,
the in-circle of the edges abc is called Ib .
5
The exterior angle bisectors of a cross section prole abc are the center of the in-circle as long as the sum
of the angles enclosed by the edges ab and bc is bigger than 2 . If the sum of the angles is smaller than 2
the exterior angle bisector intersection becomes the center of the ex-circle (see section 6.3.2.3). It signies
that the three cross section prole edges form a triangle on their concave side, which is very rare in the
convex polygonal cross section proles we use.
a)
ob
Ib
Ic
R bc
oc
I
c
I
b
R ab
R cd
z
x
b)
a
2
I abc
oabc
2
rI
2
b
Figure 6.3.4. In-circle
143
144
6.3.1.4.
can design a cross section prole of constant amplitude (see gure 6.3.5).
6.3.5 a
6.3.5 c
6.3.5 d
and a point
oa
6.3.5 b
Ia
tangent to
The construction steps a), b) and c) are repeated until the entire cross section
prole is drawn.
the two preceding edges. All in-circles are congruent and the angle bisectors are
symmetric about the edge intersections.
If we want the cross section prole to be a regular polygon the distance between the cross section vertices
i and the in-circle centers o has to be constant.
145
ob
rbI
b
i ab
R ab
oa
raI
I
oa ra
a)
b)
ob
I
b
iab
R ab
I
oa ra
c)
ob
rbI
b
i ab
R bc
oc
ibc
rcI
c
R cd
icd
rdI
R ab
I
oa ra
d)
d
a
Amax = 2r I
Figure 6.3.5. Design of convex cross section prole with constant maxi-
mum amplitude
od
146
Simplied method
It is not necessary to draw the in-circle. We can reect the cross section prole edges about
a line that originates in the in-circle center (see gure 6.3.6):
a
oa
oa
at a distance
and whose direction can be chosen arbitrarily under the condition that it
1
that corresponds to Amax . We reect the edge
2
a.
The reection of
b.
a and b is dened by their intersection
The second in-circle center ob is element of Rab and at the same distance
iab and oa .
to iab as oa .
b.
Rab
is created by a reection of
ibc
o2
and
distance to
of the edges
as
ob .
oc
a, b
and
ob .
bisector Rbc
at equal
147
ob
b
i ab
R ab
oa
oa
b)
a)
ob
b
i ab
R ab
oa
c)
i ab
oa
ibc
oc
R cd
c
icd
od
R ab
d)
R bc
ob
d
a
z
Amax = 2 oaa
Figure 6.3.6. Simplied design of convex cross section prole with con-
148
Figure 6.3.7 shows a developed and a folded surface corresponding to the cross section
prole drawn in gure 6.3.5. All vertices have six-edges and the faces in the inner pattern
rows are triangles. The frontal view shows the face edges intersecting the in-circle centers.
The face edges
e2 e3
and
f3 f4 ,
and
diamond pattern.
With
the same cross section prole but with a smaller corrugation prole amplitude, the pattern
would be composed of quadrangles and correspond to the
6.3.3).
x
z
149
y developed
i ab
oc (f 3 f 4 )
c
Rcd
icd
Rab
oa(f2 )
od (f4 )
f1
e2
e1
Amax
f2
z
x
Figure 6.3.7. Convex folded plate geometry with constant maximum amplitude
150
6.3.1.5.
erally use geometries where the amplitude of the corrugation prole is smaller or equal to
the maximum amplitude of the cross section prole:
I
Amax 5 2rmin
When the maximum amplitude of the corrugation prole is smaller than the maximum
amplitude of the corrugation prole the folded plate geometry is composed of quadrangles.
When the maximum amplitudes of the two proles correspond and the in-circle radii of
the cross section prole are constant, the folded plate geometry is composed of triangles
(see sections 6.3.1.2 and 6.3.1.4).
However it is possible to generate geometries where the maximum amplitude of the
corrugation prole exceeds the maximum amplitude of the cross section prole:
I
Amax > 2rmin
Let us consider a convex cross section prole with three edges
a, b
A>
This signies that in 3-dimensional space the side-folds and the faces
the next reection plane
and
F8
F1
and
F2
Rbc .
intersect
Rbc .
In the next step all four faces reect o the reection plane
F5 , F6 , F7
c and the
F1 , F2 with
and
Rbc
The geometry of the folded crease is composed of eight faces. Four faces are triangular
and two are pentagons. A cross section prole with three edges generates six faces, if the
amplitude of the main corrugation is smaller or equal to the maximum amplitude of the
cross section prole (see gures 6.3.10 a) and b)). Furthermore the geometry of the folded
crease is composed of four vertices instead of two.
ob
of the
side-folds two new reverse folds are generated. The reversed side-folds are oblique to the
projection plane
xz
151
f2
e2
a)
R ab
f1
F2
ob
rbI
F1
mbc
R ab
A>2r
e1
e2
b)
R ab
rbI
F1
R bc
f2
a
f1
F2
e3
ob
ob
ob
f3
F4
F3
A>2r
e1
R bc
c)
ob
rbI
R ab
f2
f1
F2
e2
F1
R bc
ob
f3
e3
ob
f4
F3
F4
F6
F5
A>2r
e1
F8
e4
F7
y
z
z
y
Figure 6.3.8. Geometry with corrugation amplitude bigger than the max-
A > 2rbI
152
To analyze the gure we divide it into three parts by parallels to the cross section
prole intersecting the vertices of the reversed side-folds (see gure 6.3.9).
The inner part corresponds to a geometry generated by a convex cross section prole
with three edges and maximum corrugation amplitude (see gure 6.3.9b)). The side-folds
are convex. Note that the cross section prole is not the mid-line of the edges.
The side-folds of the outer parts are convex and concave (see gure 6.3.9c)). They can
dierent when they are generated from left to the right than from right to the left (see
gure 6.3.10 , 6.3.11 c) and d)).
When the corrugation amplitude
tries with convex and concave side-folds and combine diamond and herringbone pattern.
Convex cross section proles with constant maximum amplitude can generate three dierent type of geometries in function of the corrugation amplitude
6.3.11):
A < 2rI :
All faces are quadrangles and the vertices have four edges. All side-folds
are convex.
A = 2rI :
The inner faces are triangles, the faces of the rst and the last row are
quadrangles. The vertices have six edges. All side-folds are convex.
A > 2rI :
The faces are pentagons and triangles and the vertices have four edges.
The side-folds are convex and concave (see appendix, gures 11.0.19, 11.0.20).
The projection of Rjp is the interior bisector of an angle formed by the edge g and the edge hr . The edge
hr is the edge h reected o Rbc .
a)
ob
Rab
Rbc
b
j
h
r
R jn
b)
ob
R ab
R bc
b
h
c)
ob
Rbc
b
j
h
k
R jp
p
z
z
y
Figure 6.3.9. Geometry with corrugation amplitude bigger than the max-
A > 2rbI .
Decomposi-
tion of the crease in three parts: a) complete geometry, b) and c) decomposed geometry.
153
154
a)
b)
c)
z
y
x
developed
Figure 6.3.10. The three types of geometries for a convex cross section
e2
f2
R ab
ob
r
I
b
155
a)
e3
f3
Rbc
c
f1
f4
e4
e1
A < 2r Ib
ob (=e2e 3)
b)
rbI
R ab f 2
f3
Rbc
f1
f4
e4
e1
A = 2r bI
ob
R ab
c)
e2
rbI
b
Rbc
f2
f3
a
f1
A > 2r Ib
e3
f4
e4
e1
e2
R ab
ob
rbI
b
Rbc
f3
a
f4
f2
e3
f1
A > 2r bI
z
x
e4
e1
Figure 6.3.11. The three types of geometries for a convex cross section
(frontal view
xz )
156
vertices alternates from convex to concave, the cross section prole forms a polygonal zigzag line. Similar to the corrugation prole the general form of a zig-zag cross section prole
is given by a mid-line around which the prole oscillates. It is either straight or curved
and can be chosen arbitrarily. To each cross section prole will correspond a maximum
amplitude of the corrugation prole.
only on the maximum amplitude of the corrugation prole but also on the depth of the
cross section prole formed by the zig-zag lines. Nevertheless it is important to control the
maximum amplitude of the cross section prole in order to manipulate the pattern and
vertex type.
The zig-zag prole generates concavities in the folded plate geometry. The cross section
prole indicates the slope of each face by the inclination of its edges. This allows control of
the slope of the faces in order to drain the rain water and to avoid concave spaces, where
water can accumulate.
6.3.2.1.
frontal view
Maximum amplitude.
xz .
a, b, c
and
and
gure 6.3.12). Due to the inversion of the vertex orientation, the bisectors are on opposite
sides of the cross section prole. The bisector
Rbc
and
c
b
a)
b)
R cd
R ab
c
b
R bc
x
y
Figure 6.3.12. Design of a zig-zag cross section prole
d.
and
157
run
on both sides of the cross section prole. They are at equal distance and parallel to the
cross section prole and reect o the external angle bisectors (see gure 6.3.13 a). Three
cross section prole edges
a, b
and
Rab
and
Rbc .
If
they are not parallel, they intersect each other and form an angle. The boundary edges
e and f of the faces reect o the bisectors within this angle. The edge f2 f3 , parallel to
b, is limited by the angle bisectors. The bigger the amplitude the shorter the edge f2 f3 .
The maximum amplitude Amax is reached when f2 f3 shrinks to a point at the intersection
of the angle bisectors oa (see gure 6.3.13 b)). Beyond that point, the boundary edge
can only reect o one of the exterior angle bisectors.
od
is more distant to the cross section prole. Consequently the boundary edge
is still
Amax
corresponds to twice the distance between the prole and the angle
bisector intersection. In an arbitrary cross section prole, this distance is dierent for each
triplex of adjoining prole edges. The maximum amplitude
Amax
twice the shortest distance between the prole and the exterior angle bisector intersection.
a)
f4
R ab
f2
oa
f3
f1
R cd
e2
e4
R bc
e3
od
d
A
2
A
2
e1
e5
f5
f4
b)
R ab
oa (f2 f3)
a
A
2
R cd
e4
R bc
d
A max
A
2
y
f1
e2
od
e3
A
e5
e1
f5
158
6.3.2.2.
geometry of the adjoining faces and their vertex. Figure 6.3.14 shows regularly corrugated
geometries corresponding to the cross section prole of gure 6.3.13 with main corrugation
amplitudes smaller and equal to the maximum amplitude of the cross section prole.
have four edges. The side-fold rows are alternating from convex to concave and point into
the same direction. They form a typical herringbone pattern.
The
dierently inclined side-folds touch each other at their tip in every second line. They form
a six-edge vertex composed of two convex main-folds and two convex as well as two concave
side-folds.
If for a given zig-zag cross section prole the amplitude of the main corrugation attains
the maximum amplitude of the cross section prole, the valence of the vertices changes
from four to six. Two four-edge vertices collapse and form a six-edge vertex. The middle
segment of the main-fold is reduced to a point which corresponds to the exterior angle
bisector intersection in the frontal view
xz .
triangle. Visually the herringbone pattern is more present with a normal amplitude. With
maximum amplitude the zig-zag character of the geometry is less pronounced.
a)
b)
x
y developed
159
160
6.3.2.3.
Ex-circle.
a, b
and
oa
of
Rab
and
Rbc
abc.
The ex-circle is tangent to one of the triangle edges and to the extension of
the two other edges (see gure 6.3.15 b). Each triangle has three ex-circles
Ec ,
Ea , Eb
and
tangent to one of the triangle edges. The center of an ex-circle is equidistant to the
three edges
a, b
and
c.
interior angle bisector, opposite to the triangle edge which is tangent to the ex-circle, and
8
Rab
with
Rbc
Ea
abc
E
Amax = 2rmin
where
E
rmin
Vertex conguration and pattern design of zig-zag polygonal cross section prole can be
controlled by the ex-circle radius.
amplitude of the main corrugation corresponds to diameter of the ex-circle, all vertices will
have six-edges and the pattern be composed of triangles. The ex-circle radius is also useful
to guarantee that the maximum amplitude of each cross section prole edge is equal or
bigger than the amplitude of given main corrugation.
Except for an isosceles triangle, the diameter of each of the three ex-circles is dierent.
a)
R cd
R ab
oa
Ea
Ed
c
b
raE
d
a
R bc
od
rdE
x
y
b)
Ec
1802
oc
c
1802
2
b
rcE
161
162
6.3.2.4.
we can design a cross section prole with constant amplitude (see gure 6.3.16).
6.3.16
6.3.16
6.3.16
6.3.16
a)
Ea
oa
raE
b
a
b)
Ea
R ab
oa
raE
b
a
c)
Ea
R ab
oa
raE
d)
Ea
R ab
oa
raE
R bc
od
e)
oc
Ea
Rab
oa
Rcd
b
raE
Ed
R bc
od
d
rdE
A max =2r E
y
Figure 6.3.16. Design of a zig-zag cross section prole with constant amplitude
163
164
Simplied method
cross section prole with constant amplitude can be simplied (see gure 6.3.17).
The
edges of the cross section prole are reected about a line that originates in the ex-circle
center:
6.3.17 a) We draw a rst cross section prole edge
1
that corresponds to Amax . We reect the edge
2
oa
at a distance to
and whose direction can be chosen arbitrarily under condition that it intersects
6.3.17
6.3.17
6.3.17
a.
The reection of
6.3.17 e) By repeating the steps b) and c) we can complete the cross section prole.
a)
oa
b
b)
i ab
oa
R ab
b
c)
i ab R ab
oa
b
a
d)
i ab R ab
b
oa
c
R bc
i bc
e)
oc
Rcd
i ab R ab
oa
R bc
a
i bc
od
d
A max =2oaa
y
Figure 6.3.17. Simplied design of a zig-zag cross section prole with
constant amplitude
165
166
The developed and the folded surface corresponding to the cross section prole of gure
6.3.16 is shown in gure 6.3.18. The faces of the inner rows are triangles and form a dart
pattern. The vertices at the point of the darts have six-edges.
The frontal view
xz
and
f2 f3
and
e3 e4
parallel to the
edges does not show the orientation inversion of the cross section prole.
167
a)
+
x
y developed
b)
oc (f 4)
o a(f 2 f3 )
f1
e2
R bc
od (e 3e4 )
A max
A max
A
2
e1
A
2
R cd
R ab
e1
f5
x
Figure 6.3.18. Zig-zag folded plate geometry with constant maximum amplitude
168
6.3.2.5.
a,b
and
c,
1 < 2
and
Ea ,
and
, as
c, tangent to Ea , can
Rbc within an angle ,
Suppose we want
c)9.
bisector
If we design a cross section prole with more than three edges, the ex-circles
will be alternatively tangent to the rst or to the last of the three edges that
Ea (abc)
1 = 2
The edges
Rab
and
Rbc
an
is concave.
are parallel too and do not intersect (see gure 6.3.19 b)).
The
amplitude of the corrugation is not limited and its general extension straight.
This conguration corresponds to the geometry rst described by
and called
1 > 2
Miura Ori.
Miura [Miu70]
Suppose we want
to design cross section prole with constant maximum amplitude, with the edges
and
b,
Ea
set.
can be chosen
three edges, the ex-circles will be alternatively tangent to the rst or to the last
Ec tangent to
c the position of the ex-circles is the following: Ec (abc) , Eb (bcd) , Ee (cde)
, Ed (def ) ,Eg (ef g) (see gure 6.3.21). If 1 is convex, the general curvature of
the cross section prole will be concave and inversely it will be convex if 1 is
of the three edges that dene the ex-circle. With the rst ex-circle
edge
concave.
By denition the ex-circle is tangent to the three lines a, b and c, but it only touches one edge of the
triangle and is tangent to the extension of the other edges (see gure 6.3.15)
169
Ea
oa
a)
a
b
b'
R ab
b'
R ab
2
R bc
R bc
b)
R ab
R ab
a
b
R bc
R bc
c)
R ab
R ab
a
1
R bc
R bc
r Ec
oc
Ec
x
y
6.3.19
Figure 6.3.19. Ex-circle position
170
The folded and the developed geometries corresponding to the cross section proles
of gure 6.3.19 are shown in gure 6.3.20.
three proles and therefore the geometry of the rst side-fold row is identical for the three
patterns.
1 < 2
The convex vertices of the rst and the second side-fold rows coincide.
The
1 = 2
1 > 2
The side-fold rows are parallel and the side-fold angle are equal:
1 = 2
The concave vertices of the two side-folded ranges coincide and relationship between the side-fold angles
is inverted :
1 < 2 >
faces is limited even when the dierence between the bending angles
becomes important.
and
171
1
2
y developed
Figure 6.3.20. Consequences of ex-circle position on folded geometry and
developed pattern
172
z
y
x
Ra
oa
Ec
R ab
oc
R bc
R cd
d
R de
e
R ef
od
of
Ef
x
y developed
1 < 2
Ed
173
Eg
og
+
R ef
oe
ob
Ee
d
Rde
R bc
Eb
R cd
Rab
R fg
od
Ed
oc
Ec
x
y developed
1 > 2
174
6.3.2.6.
prole
a, b, c
and
in a single vertex
d can have three exterior angle bisectors Rab , Rbc and Rcd that intersect
oa : the triangles abc and bcd have a common ex-circle Ea = Eb to which
all edges are tangent. As a consequence, the convex vertices of three side-fold rows coincide
in the folded geometry. The two main-fold edges and the side fold edges form an 8-edge
vertex with one convex and one concave main-fold edge as well as two concave and four
1 < 2 , all
section prole are growing in size: 1 < 2 < 3 . Inversely
of the cross section prole decrease in size: 1 > 2 > 3 .
convex side-fold edges (see gure 6.3.23 and appendix, gure 11.0.15).
bending angles of such a cross
if
1 > 2 ,
If
The number of exterior angle bisectors intersecting in a single vertex could be increased.
175
a)
+
y developed
oa=ob(f 2 f3 f 4)
R ab
b)
e2
R cd
b
f1
a
A max
Rbc
e4
e3
e5
A max
A
2
A
2
e1
z
x
Figure 6.3.23. Herringbone pattern with 8 edge vertices
f5
176
6.3.2.7.
is possible to generate geometries where the maximum amplitude of the corrugation prole
exceeds the maximum amplitude of the cross section prole:
E
Amax > 2rmin
Let us consider a zig-zag cross section prole with three edges
and
and the
A>
Rbc .
xz ,
f1 f2
This signies that in 3-dimensional space the side-folds and the faces
Rbc
F1
F2
and
Rbc into eight faces. The poly surface is split in an unusual way. The
faces F3 , F4 , F5 and F6 in the middle of the poly-surface are above the reection plane and
the F1 , F2 , F7 and F8 are below the reection plane Rbc (see gure 6.3.24 b)). Normally a
reection plane splits a crease in two parts, where one end of the poly-surface is below, and
the other end above the reection plane. In order to constitute a continuous poly-surface,
the faces on both ends,
plane
Rbc .
F1,
and
F2 ,
F1
as well as
and
F2
F7
and
F8 ,
of the
cross section prole. In order to nd a correspondence between the cross section prole
and the folded surface, the edge
new cross section prole
ar abc
Rbc .
Rbc .
This
The so folded
crease is composed of six side-folds instead of four. The reections about the plane
generate two additional side-folds
the side folds
and
s2
s1
and
s2
s5
and
ss .
s1 , s2
splits
in two parts. Like a main fold, one part of the convex side folds
Rbc
Rbc
s5 , s6
s1
generate three additional vertices. The folded crease has ve inner
vertices. The poly-surface of the folded crease is composed of eight faces. Four faces are
triangular and four are pentagons.
177
e2
a)
f2
F1
F2
oa
R ab
raE
e1
R bc
A>2raE
R ab
f1
b)
f2
E
a
oa r
R ab
e2
e1
F1
F2
oa
s2
oa
s1
R bc
f1
A>2raE
f3
R bc
F4
F3
e3
F2
c)
s1(+)
e3
A>2raE
e1
Rab
e2
f3
oa
raE
a
f2
f4
oa
s5 s6
s1(-)
s3
f1
ar
oa
F1
f5
s1(+)
s1(-)
s4
F4
F6
F3
F5
R bc
F7
A > 2rb
F8
178
To analyze the gure we split it into three parts by parallels to the cross section prole
intersecting the side-folds intersections (see gure 6.3.25 a)). The inner part corresponds
to a geometry generated by a zig-zag cross section prole with four edges and maximum
corrugation amplitude (see gure 6.3.25 b)). The side-folds are convex and concave. The
geometry is similar to geometry generated with a cross section prole with eight-edge
vertices described in section 6.3.2.6.
The exterior parts can be generated by a convex cross section prole with two edges
k.
and
The edge
r
is parallel to a , the reection of
about
Rbc ,
and
parallel to
c.
The
A > 2rI
6.3.1.5) is inverted: the inner part of the gure can be generated with a zig-
zag cross section prole and the exterior parts with convex cross section proles. Although
this geometry is theoretically possible, it is dicult to control it in practice.
Indeed,
when the number of edges of the cross section prole is increased, the number of sidefolds intersecting multiple reection planes increases and the geometry becomes dicult
to control.
The order in which the geometry is generated is important. It is dierent when generated from the left to the right, than from the right to the left (see gures 6.3.26 c) and
6.3.27 c)).
Zig-zag cross section proles with constant maximum amplitude can generate three dierent type of geometries in function of the corrugation amplitude
6.3.27):
A < 2rE
A=
2rE The inner faces are triangles, the faces of the rst and the last row are quadran-
A>
2rE The faces are pentagons and triangles and the vertices have four-edges.
gles. The vertices have six edges. The side-folds are convex and concave.
The
a)
A>2raE
R hrg
hr
Rab
h
z
ar
g c
oa
R bc
b)
hr
Rab
h
ar
g c
oa
R bc
c)
R hrg
hr
j
h
oa
R bc
z
y
A > 2raE .
De-
179
180
a)
b)
c)
z
x
A > 2rE .
Devel-
181
e4
a)
f4
c
R ab
f2
oa e2
raE
e3 b
f3
e1
A<2raE
R bc
f1
e4
b)
f4
c
R ab
f2
oa(=e2,e3 )
b
raE
e1
f3
A=2raE
R bc
f1
e3
A>2raE
f1
c)
e1
e2
R ab
f3
oa
raE
f5
f2
f4
R bc
e2
oa
R ab
f3
raE
f2
e1
e4
b
e3
R bc
A>2raE
z
f1
e5
x
Figure 6.3.27. Geometry with corrugation amplitude greater than the
xz
A > 2rE .
182
6.4. Discussion
The cross section prole is an interesting tool to design and control the general shape
of a folded plate geometry. It directly draws the section of a space. Functional and spatial
parameters can be integrated into the design.
Structural considerations can be taken into account by the shape of the prole, favoring
a direct load transmission to the ground, but also by the control of the corrugation amplitude. It is possible to design cross section proles which guarantee a desired corrugation
amplitude in all points and thus control the structural depth (see appendix, gure 11.0.2).
The structural strength will not only depend on the corrugation amplitude but also on the
inclination of the corrugation edges (see appendix, gure 11.0.8).
The transverse inclination of the faces, composing the folded plate geometry, can also be
controlled by the cross section prole. This guarantees that rain water is always naturally
drained to the ground.
The general shape is limited to cylinder surfaces. For cross section proles with big
maximum amplitude the cylinder shape can be modied by the geometry of the corrugation prole. In such geometries the corrugation mid-line is like a corrugation at a bigger
scale: big folds, modifying the general shape, are superposed on small folds, corrugating
the surface.
This is adapted to simple cross section proles with few edges, where the
undulation of the general form can have a real visual and spatial impact.
Nevertheless
the geometries stay restricted to cylinder surfaces that oscillate more or less close to the
reference surface. This restriction is due to two factors:
Vertex geometry
main-folds, which means that the vertices are always composed of two edges that form
a continuous, main-fold and two oblique side-folds. A more general model presented by
Tac09] is able to take into consideration four-edges vertices with arbitrary congu-
Tachi [
rations. This allows double-curved surfaces. Their form generation is more complex than
the method we propose and they do not have the advantage of being cut out of parallel
strips.
surfaces, composed of multiple patches, can be modeled (see appendix, gures 11.0.21,
11.0.22). Particularly rotational surfaces, which are close to the shapes that can be obtained by deforming paper models, can be generated (see appendix, gures 11.0.23, 11.0.24,
11.0.25). Doubly-curved diamond surfaces can also be designed by a method proposed by
Thonon [Ton93].
Future work may show how to simplify its method in order to integrate
Hexagonal Pattern
6.4. DISCUSSION
Herringbone Pattern
183
Combinations of convex and concave folds can be used to create various other patterns.
To each cross section prole corresponds a maximum amplitude which sets the maximum amplitude of the corrugation prole. The maximum amplitude can be controlled by
the in-circle, for convex polygonal cross section proles, and by the ex-circle, for zig-zag
cross section proles.
mum amplitude change: two adjoining vertices collapse and form a six-edge vertex and
the quadrangular faces of the pattern become triangular. The control of the amplitude is
important to guarantee a structural depth, and to control the pattern type. Furthermore
it is important to ensure a given amplitude of the cross section prole when the shape of
the corrugation prole is irregular, for example, if its mid-line is curved or polygonal. In
this case the pattern type is not, or only locally, modied (see chapter 9, gure 9.2.2).
The control of convex polygonal cross section proles with constant maximum amplitude is not much constraint: there is lots of freedom to choose the direction of the prole
edges and the form of the cross section prole is close to the shape of the folded plate
geometry.
The control of zig-zag cross section proles with constant amplitude is more delicate.
The fact that two ex-circles can be chosen as reference for a new edge, and that its direction
is more limited, makes the control of the general shape dicult. With constant maximum
amplitude the zig-zag shape of the main-fold disappears and the side-folds characterize
the general form. Therefore, the cross section prole, even though it generates the form,
is not always directly representing the general shape.
triangles with acute angles. For timber construction these angles might be problematic for
assembling, handling and transport.
CHAPTER 7
Oset
7.1. Introduction
To build the generated polygonal surfaces with timber panels we have to give a thickness
to the surface.
thickness and therefore create an oset of all the faces at equal distance (see gure 7.1.1).
In polygonal surfaces, the face edges meet in a vertex.
edges of the oset faces should ideally meet in a single vertex again. This only happens
under certain conditions depending on the geometry and the topology of the vertex. In the
folded plate geometries that we are interested in, mainly two vertex types appear: the most
common, the four-edge vertex, directly stems from the reverse fold. When the corrugation
amplitude corresponds to the maximal amplitude of the cross section prole two four-edge
vertices collapse and form a six-edge vertex.
First oset in both types of vertices were investigated. We found that six-edge vertices
cannot be oset with all the edges intersecting in one vertex.
the oset of the faces with edges intersecting in a single vertex is possible under certain
conditions. It is interesting to note that these conditions depend on whether the geometry
is completely foldable or not. If the inclination angles of the faces are symmetric, which
means the geometry is completely foldable, the oset in a single vertex is possible. In the
following, we will describe the oset conditions of both, four-edge and six-edge vertices
in symmetric and asymmetric position and some consequences for the generation of the
geometry for folded plate structures.
186
7. OFFSET
The distance is measured on the normal to both surfaces. In a poly-surface, all faces
are oset with the same distance, normal to the original faces.
Let us consider two faces
normals to the faces
a plane
n1
and
F1 and F2
n2 indicate
e12
e12 ,
P.
bisector
b12
which is perpendicular to
P.
n1
and
n2 ,
b12
e12
form a right
angle.
In reverse folds, four faces form a four-edge vertex. The oset faces intersect in a single
vertex under condition that the bisector planes of all faces intersect in a single edge.
187
B
P
e'12
F'1
e12
n1
b12
F'2
n2
F1
F2
z
y
x
B
e'12
F'1
n1
b12
F'2
n2
e12
d
F1
F2
x
Figure 7.2.1. Oset for two faces
188
7. OFFSET
F1
F2
F3
and
F4
n1
n2
n3
and
n4
(see gure 7.2.2). We position the origin of all normals on the vertex such as they indicate
the dihedral angle between the four faces and dene the interior angle bisectors
b23
and
b14 .
The faces
e24 .
b12 , b34 ,
F3
and
F4
n1
and
n3 ,
respectively
n2
and
R, nR (see gure 7.2.3). The normal nR is the interior angle bisector of the
angles n1 n3 and n2 n4 and the intersection of the bisector planes B13 and B24 .
The bisector planes B12 and B34 have to intersect in nR too, so that all bisector planes
intersect in a single edge. The normal nR is also the interior bisector of the angle enclosed
by the main-fold edges e12 and e34 (see section 5.5.2.3). In order to intersect with the
normal nR the bisector planes B12 and B34 have to form a single plane, congruent with
the crease edge plane M , dened by the main-fold edges e12 and e34 . This is the case when
the faces F1 and F2 , respectively F3 and F4 , are symmetric to the crease edge plane M
normal to
The symmetric reverse fold can be oset. It fullls the conditions for an oset formulated
by
2 + 1 = 1 + 2
n2
e 13
n1
F1
n2
F2
F3
F1
e 12
F2
b12
n3
1
F3
e 24
n1
F4
2
F4
n3
nR = b13 = b24
e 34
n4
b34
n4
y
nR = b13 = b 24
n1 n2
189
n3 n4
F1 F2
F3 F4
bisector planes
B13
and
nr
is intersection of the
B24
F'1
F'2
B12
B13
nR
B23
B34
F'3
F'4
y
190
7. OFFSET
e12
and
e34
nr
is not congruent with the bisector planes. The sums of the opposite angles are not equal,
1 and 2
e034
and
M.
B12
and
B34
are rotated
e012
B12
and
B13 ,
as well as
B24
and
B34 ,
do intersect.
There is a triangular gap between the two intersections that indicates the shift of the oset
main crease edges
F20 and
e012
and
e034 .
F10
and
F40
For osets of asymmetric reverse folds, the main-fold edges are shifted and the resulting
poly-surface has two inner vertices. This happens independently to the side on which the
surface is oset (see gure 7.2.7).
e'12
F1
n1
B34
e12
F2
B12
F1
n2
e'34
e'12
e
F3
B12
F3
F2
F4
e34
F4
n4
nR
B34
n3
a)
b)
e'34
z x
y
F2
191
F'1
F1
F2
B12
B13
B24
F'2
e'12
e'13
F4
e'24
F3
B34
F'3
F'4
e'34
y
b)
a)
z x
Figure 7.2.6. Bisector planes and oset faces of asymmetric reverse fold
B12
F1
F2
B13
B24
B34
F3
F4
Figure 7.2.7. Bisector planes and oset faces of asymmetric reverse fold
192
7. OFFSET
In convex polygonal cross section proles, the side-fold arrows are opposite. The
side folds form an x crossed by the straight main-fold.
In zig-zag cross section proles the side-fold arrows have the same direction. The
side folds form a double arrow crossed by the straight main-fold.
It has been shown that the only possible intersection of the bisector planes of a four-edge
vertex is the normal to the reection plane. If two reection planes intersect, as happens
in the case of six edge vertices, they do not have a common normal. Therefore, six-edge
vertices cannot be oset such as the oset faces intersect in single vertex.
six-edge vertex, can be oset if it is symmetric. We show the consequences on the oset
surface, if the two vertices collapse, for the two vertex congurations:
7.3.1.1.
nR1
and
nR2
Convex side
(see gure 7.3.1 a)) The angle between the normals is opening and the two
oset vertices move away from each other. The middle main edge segment
e34 ,
that disappeared in the original surface, reappears in the oset surface forming a
hexagonal pattern. The oset surface looks like a folded surface with two reverse
folds that have non-maximal amplitude.
Concave side
(see gure 7.3.1 b)) The normals intersect each other and the oset vertices
of each reverse fold penetrate into the opposite oset surface. Therefore, the sidefold edges
plane
M.
e13
and
e35
as well as
e24
and
e46
nR2
193
nR1
nR1
nR2
e'56
e'12
e56
e56
e12
e12
e'56
F'1
e'12
F'2
e'12
F'2
F'1
e'12
F'3
e'34
e'13
F'4
F'3
e'24
F'4
e'35
e'56
e'46
F'6
F'5
e'56
F'5
F'6
a)
b)
Figure 7.3.1. Six-edge vertex with convex polygonal cross section prole
194
7. OFFSET
7.3.1.2.
polygonal prole: if the surface is oset to the convex side, the middle segment of the
main-fold edge reappears forming a herringbone pattern.
corrugation amplitude would not be maximal (see gure 7.3.2 a)). If the surface is oset
to the concave side, the vertices of the side-folds intersect and the oset faces are truncated
(see gure 7.3.2 b)).
nR1
nR2
nR1
nR2
e'12
e12
e12
e'56
e56
e'12
e56
e'56
F'1
e'12
F'2
e'34
e'12
F'3
F'1
F'4
F'2
F'3
e'56
F'4
e'56
F'5
F'6
F'5
y
a)
F'6
zy
z x
b)
Figure 7.3.2. Six edge vertex with zig-zag cross section prole and sym-
metric corrugation
195
Convex
(see gure 7.3.3 a) and 7.3.4 a)) For osets to the convex side the oset vertices
move away from each other and the reappearing edge of the main-fold is shifted
relative to the crease edge plane
M.
F40
Concave
(see gure 7.3.3 b) and 7.3.4 b)) The osets to the concave side have a similar
conguration as symmetric six-edge vertices, except that the side-folds do intersect
in asymmetric positions to the main-fold edge. In the case of zig-zag cross section
prole we observed strong dierences in the oset conguration depending on the
bending angles.
nR2
nR1
nR2
e'56
nR1
e'12
e56
e56
e12
e'56
F'1
a)
e12
e'12
b)
e'12
F'2
F'3
F'1
F'2
e'12
e'34
F'4
F'3
F'4
e'56
e'56
F'6
F'5
F'6
F'5
z
x
Figure 7.3.3. Six-edge vertex with convex polygonal cross section prole
196
7. OFFSET
nR2
nR1
nR2
e'12
nR1
e12
e12
e'56
e56
e'12
e56
e'56
e'12
F'1
F'2
e'34
F'3
F'2
F'1
e'12
F'4
F'4
F'3
e'56
e'56
F'5
F'6
z
F'6
F'5
y
x
a)
b)
Figure 7.3.4. Six-edge vertex with zigzag cross section prole and asym-
metric corrugation
7.4. DISCUSSION
197
7.4. Discussion
The oset of four-edge vertices is only possible for symmetric folds. With asymmetric
folds the oset main-fold edge is shifted realtive to the crease edge plane
fold.
at each reverse
The distance of
shifting depends on the degree of asymmetry and on the oset distance. It has important
consequences for the conception of folded plate geometries.
When the vertex conguration inside and outside of a folded plate structure has to
be identical, the edges of the corrugation prole must have constant inclination angles.
This means that only completely foldable geometries can be oset such as the vertex
conguration is the same on both sides. Furthermore, only parallel corrugations can be
used. Oblique folds are asymmetric and cannot be oset in a single vertex. This is also
a strong constraint from an engineering point of view: it does not allow one to incline
some faces more strongly in order to strengthen the structure. Nevertheless, we can still
increase the amplitude of some folds. From a construction point of view this restriction
might be a simplication: the bisector planes of all main-fold edges have the same angle
which facilitates the assembling and simplies the connections between main-folds (see
chapter 9, gure 9.3.1 f ) and 9.4.2)).
In case of asymmetric folds, a decision has to be made whether the single vertices
are outside or inside of the initial poly-surface.
exact composition of the construction has to be known in order to dene the denitive
geometry of the structure. When the structure can be visible inside, which is one of the
big advantages of folded plate timber structures, we suggest to have the original geometries
inside and to oset to the outside.
the main-fold edge might be very small so that it may not be considered by the carpenter.
This could lead to problems of tolerances during the assembling. The shift of the main-fold
edge can also be considered as a positive element and give a special tectonic to a folded
plate structure (see appendix gure 11.0.26).
If the maximum amplitude of the cross section prole is constant and correponds
to the amplitude of the main corrugation, only regular corrugation proles with constant
inclination angles
are reasonable.
The oset surface restores a geometry with non-maximal amplitude whereas the oset to
the concave side introduces a new tectonic which is not in the nature of the original surface.
With irregular inclination angles
the sharpness of the original geometry. The geometry of the oset faces becomes complex
and seems more dicult to build.
An alternative for the oset vertex conguration might be the method proposed by
Stotz [Sto09].
He cuts the edges of all faces such as on the original side they meet in a
single vertex and on the oset side they form a negative pyramid.
1
This is only possible for convex polygonal cross section proles since zig-zag cross section proles are
convex and concave by denition.
198
7. OFFSET
conguration on the oset surface right from the beginning of the design process (see
chapter 9).
Part 3
Prototypes
CHAPTER 8
Plywood Prototype 01
8.1. Introduction
The construction of a rst prototype (see gure 8.1.1) was eected quite early in the
thesis study and had three goals:
First
Secondly
To compare the deformation and the load capacity of the prototype with modeling of three dierent Finite Element Programs.
Thirdly
To collect rst experiences with the connections of plates and the assembling
process.
202
8. PLYWOOD PROTOTYPE 01
8.2. Geometry
The geometry of the folded plate structure is dened by a regular corrugation prole
with the following parameters (see gure 8.2.1):
= 30
Amplitude A = 138.6 mm
Interval I = 240 mm
Width W = 277 mm
Total Interval Itot = 2880 mm
Inclination angle
The cross section prole describes a segment of a circle and has the following parameters
(see gure 8.2.1):
r = 3351 mm
span: s = 6462 mm
clearance height: h = 2362.7 mm
bending angle: = 135
edge length: e = 749.6 mm for the
radius of circle:
e = 586.9 mm
edges
At the time we did not have a CNC milling machine at our disposal and the faces had to
be cut by hand. Therefore the geometry is composed of a single face and its symmetrical
part. The only exception are the faces touching the ground which are cut horizontally in
order to form a linear support. In total, the folded plate geometry is composed of 144 faces
that form 12 arcs with 12 faces. The basic form is a trapezoid with two parallel sides of
960 mm respectively 530 mm of length and a width of 277 mm. The acute, opposite angles
of the triangle have 20 and 40 degree respectively.
The thickness of the panels is 21 mm : they are designed with a miter cut. Due to the
constant inclination angle of the corrugation edges the oset did not cause problems.
8.3. Model
The correctness of the geometry and its oset where tested in a reduced scale (see
gure 8.3.1). The model, composed of 6 arches with 12 panels and an approximate span
of
2000 mm,
connected by screws and there were few imprecisions due to milling. The structure could
easily support the author's weight.
In a second step, 6 elements where fabricated and assembled at full scale. Again the
precision was satisfying but it showed the necessity of falsework for the assembling of the
nal structure.
8.4. Joints
The panels were assembled by self drilling screws ( 5 mm,
every
l = 80mm
) , arranged
not correspond to the norms (the screws are parallel to the bers and the distance to the
edge of the panel is too short) it seemed well adapted because the assembling was very
8.4. JOINTS
203
y
x
=2
77
.1
A=138.6
=30.0
I=240.0
e=749.6
=135
h=2362.7
e=586.9
r=3351.0
s=6462.0
z
x
140
20
160
40
277
534
y
x developed
965
204
8. PLYWOOD PROTOTYPE 01
easy and the panels do not split because the screws are self drilling. The bending stiness
of this connection was evaluated in a series of four preliminary tests. This was necessary
to determine the spring resistance of the joint that could then be used in the structural
modeling. Therefore two panels were assembled in a V-shape and put under vertical load.
The relation between the vertical deformation and the load allowed us to dene the spring
resistance
produces the mirrored counterpart. Templates have been used for the accurateness of the
milling. Nevertheless small errors and imprecisions appeared.
1
mm
( K,ser = 3.953 106 Nrad
)
Figure 8.3.1. a) Model of the prototype b) four elements form a reverse fold
a)
c)
b)
screw 5,0 / 80
205
For the assembling, two symmetrical trapezoids are connected along their parallel sides
to V-shapes with the help of falsework (see gure 8.5.2 a).
along their long side form a piece with an acute vertex and an obtuse dovetail, inversely,
assembled along their short side, they have an obtuse vertex and an acute dovetail (see
gure 8.5.1 b) and c)).
These two basic elements are again assembled with the help of
falsework to a piece that forms a reverse fold with four faces (see gure 8.5.2 b) and
8.3.1 b)). In the next step, six reverse folds are assembled lying horizontally on their side
to a complete arc of the structure. The following two arcs were assembled on top of the
rst. These three arcs, which make half of the structure, were erected and connected with
their counterpart to form the complete barrel vault.
Elements of uncertainty during the construction of the prototype were the precision of
the the milling and of the assembling. It has been shown that the panels were suciently
precise and that the V-shape and reverse fold elements were exible enough to tolerate small
errors. The fact that individual elements are relatively exible, and that the stiness of the
structure increases with the number of assembled elements, is an advantage of folded plate
structures.
It allows fabrication of panels with high precision and creates the necessary
assembled V-shapes
206
8. PLYWOOD PROTOTYPE 01
tolerances for the assembling, with the exibility of the individual elements. This has to
be veried on larger scale structures.
PW06, NPW06].
small loads [
8.6.1)
(1) Symmetrical load in the center of the arc on 4 side-folds (charge Fates):
41, 0 kN
(2) Asymmetrical load on the north side of the arc on 2 main-folds (charge Nord):
2 2.2 kN
(3) Asymmetrical load on the south side of the arc on 3 main-folds (charge Sud) :
3 2.2 kN
A series of sensors measured the vertical displacement of the structure during the load
tests (see gure 8.6.1).
At the end of the deformation tests we increased the loads until rupture of the structure.
The loads were introduced simultaneously on the north and the south sides. Even though
positions of the load introduction are symmetric they oer dierent support conditions.
In fact convex and concave folds invert in the center of the barrel vault, so that the load
in the north can be introduced on two main-folds and in the south on three main-folds,
which leads to an asymmetric load introduction. The rupture started with a load of
27 kN
when the concave main-folds in the center, close to the southern load introduction, began
to rip open (see gure 8.6.1 and 8.6.2 a)). As was the load introduction, the deformation
was asymmetric: in the second phase of rupture, the barrel vault was strongly pushed to
the south side and the convex main-folds near the support ripped open (see gure 8.6.1
and 8.6.2 b)). The failure of the structure was clearly due to an insucient distance of the
screws to the edge of the panels (see gure 8.6.3)
207
Charge Nord
load introduction
Charge Fates
sensor
failure zone a
failure zone b
Charge Sud
lated on three dierent Finite Element FE software applications (SAP, RFEM, ANSYS).
convex fold
concave fold
Figure 8.6.1. Load introduction points, situation of the sensors and fail-
ure zones
208
8. PLYWOOD PROTOTYPE 01
PW06, NPW06] .
Four dier-
ent loadings, corresponding to the three loadings of the prototype and to its dead weight,
have been calculated. The comparison of the results shows big dierences between the software applications (see table 1). One element that strongly inuences the outcome is the
rotation freedom of the joints. When the rotations are blocked two software applications
show similar results (see table 1 lower lines). When the joints are modeled as hinges with
free rotations, the results strongly dier (see table 1 upper lines). The planned folded plate
structures can hardly be realized with rotational sti joints. A certain rotational freedom
always has to be allowed and ideally the joints are free for rotations which simplies the
connection between two panels.
An other element that inuences the simulation is the mesh size used in the FE software.
Preliminary calculations on single plates showed that, due to the acute angles of
the plates, a strongly rened mesh with smalls elements has to be used. This slows down
the calculation and might also inuence the result in the sense that it stiens the overall
structure.
The comparison between the deformations of the prototype and the calculations, which
considered the relative bending stiness of the joints evaluated in the preliminary tests,
showed that the prototype is much more exible than the predictions of the calculations
indicate (see table 2) .
8.8. DISCUSSION
209
8.8. Discussion
The construction of the prototype showed the feasibility of folded plate structures based
on origami geometries. In regard to the complexity of the structure, the fabrication and
the assembly did not cause particular problems. The exibility of the elements seems to
be able to absorb small variations in fabrication and assembly.
The failure mode of the structure showed:
The comparison of the dierent calculation software applications showed that further research needs to be done in order understand and correctly simulate the structural behavior
of folded plate structures.
The fact that the prototype is much more exible than the results of the calculations,
indicates that the joints have to be considered as hinges with rotational freedom.
This
would also be an economic advantage because such connections are easier to realize.
HW07,
These results engaged new engineering research for folded plate structures [
CHAPTER 9
Plywood Prototype 02
9.1. Introduction
The second prototype was designed for an exhibition. Its goal was to illustrate the possibilities of shaping forms with the origami-based form generation method. The intention
was to show a geometry whose general form varies and oers dierent perceptions when
turning around the object. Furthermore the suitability of such geometries for integrated
manufacturing should be demonstrated by applying the tools developed by
Sto09].
thesis work [
Ivo Stotz
in his
212
9. PLYWOOD PROTOTYPE 02
9.2. Geometry
The form is a vertical, polygonal cylinder whose shape varies from the ground to the
top. The cylinder is not closed, so that the visitor can perceive the inside of the object.
The form is inspired by a regularly curved paper folding put on its small side and which,
due to the suppleness of the paper, describes a spiral (see gure 9.1.1). It plays with the
ambiguity of the inside outside perception inherent to folded geometries: a convex fold seen
from outside becomes concave inside. Every fold is simultaneously inside and outside, and
reverses from concave to convex when changing direction. This perception is accentuated
by the spiral form and gives the geometry the quality of an innite surface that returns on
itself, similar to a Mbius strip.
In order to vary the general shape, the corrugation mid-line is slightly curved. This
squeezes the faces alternatively inside and outside (see gure 9.2.1).
oset equidistant to each side, which keeps the amplitude constant.
corrugation prole was drawn within the two oset curves. Because the object was visible
from inside and outside, we wanted to have the same vertex type on each side. Therefore
the inclination angles
simply-corrugated surface are parallel (see gure 9.2.2). In combination with the constant
amplitude
a constant inclination angle has an other advantage: all bisector planes are parallel, in this
case parallel to the ground, which facilitates the mounting and assembling of the structure.
Every row of faces can be assembled independently on a horizontal surface and then piled
up. The maximal amplitude of the corrugation prole is the horizontal distance between
the outermost vertex
f.
The cross section prole is a six-edge polygonal line. The maximal possible amplitude
varies for each edge. The cross section prole was designed so that the amplitude of each
edge (A2 ,
A3 , A 4 , A 5 )
Amax .
This guarantees that all faces are quadrangular and all vertices have four edges (see gure
9.2.2).
9.2. GEOMETRY
213
A
I12
I11
i4
I10
A4
I9
R 34
R 45
I8
e4
i3
I7
A3
e3
e5
I6
i5
e6
I5
R 23
R 56
e2
I4
I3
A5
f'
e1
A2
i2
x
A max
g'
R 12
I2
I1
= 60
A max
W12
W11
W10
W9
W8
W7
W6
W5
W4
W3
z
+
x developed
W2
W1
1
214
9. PLYWOOD PROTOTYPE 02
Oset
2500 1250 mm
21 mm
Starting from the poly-surface the faces have been oset automatically by the
help of a script. For general planar, quadrangular meshes, the oset in a single
vertex is not possible. In this case the corners of the panels are cut by a triangular
Sto09].
By choosing a
constant inclination angle we could guarantee the oset in a single vertex for all
faces and adapt the script to this particular situation
Addressing
All panels were identied by an address number composed by the line and the
Panel layout
They were laid out by lines on seven plywood panels (see gure 9.3.1 a)).
The fact that the basic geometry can be developed as a single, continuous surface
helped to organize the faces on the panels with a minimum of waste. This is an
important advantage for the economic construction of folded plate structures.
Tool path
The order of milling operations and the tool path were generated by a second
Machine code A script translates the tool path into the machine code (see gure 9.3.1 c)).
Milling The machine code is tested 50cm below the machine table and with low speed to
evaluate its correctness. The faces were milled within a day. Each face is marked
by its number (see gure 9.3.1 d)).
Assembling
The faces were assembled horizontally by lines (see gure 9.3.1 e) and f )).
They are joined by dowels and glue. Some screws had to be added to keep the
faces in place. Stickers were used to control the position of the faces during the
handling and the transport. The lines have been piled up and connected by dowels
drilled with a lamello machine. The folded plate structure has been transported
in two pieces that were assembled in place.
The scripts to generate the oset mesh, the tool path and the machine code were developed by Ivo Stotz
[Sto09]
215
a) panel layout
p1_t ool _1
P671002
N10 G0 G66 F2000 Z- 29
N15 G47
N20 T40 M6
N25 G47 A0 B0
N30 S16000 M3
N35 G49
N40 G54 G0 X0 Y0 Z80 A0 B0
N45 ( Cont our c ut of par t number : 12: 3)
N50 G0 X500. 8012 Y1272. 1528 Z55. 1753 A35. 984 B45. 851
N55 G1 X482. 0376 Y1297. 9939 Z24. 1753 F1000
N60 G1 X74. 5779 Y1002. 1306 Z24. 1753 F4000
N65 G1 X69. 7357 Y1008. 7993 Z16. 1753 F1000
N70 G1 X477. 1954 Y1304. 6625 Z16. 1753 F4000
N75 G1 X471. 7478 Y1312. 1648 Z7. 1753 F1000
N80 G1 X64. 2882 Y1016. 3015 Z7. 1753 F4000
N85 G1 X93. 3416 Y976. 2895 Z55. 1753 F4000
N90 G0 X88. 8791 Y1010. 6654 Z53. 1781 A90 B31. 1856
N95 G1 X70. 1155 Y1010. 6654 Z22. 1781 F1000
N100 G1 X70. 1155 Y221. 8432 Z22. 1781 F4000
N105 G1 X65. 2733 Y221. 8432 Z14. 1781 F1000
N110 G1 X65. 2733 Y1010. 6654 Z14. 1781 F4000
N115 G1 X59. 8258 Y1010. 6654 Z5. 1781 F1000
N120 G1 X59. 8258 Y221. 8432 Z5. 1781 F4000
N125 G1 X88. 8791 Y221. 8432 Z53. 1781 F4000
N130 G0 X94. 426 Y269. 1184 Z55. 8193 A- 28. 852 B- 51. 4372
N135 G1 X75. 6624 Y235. 0603 Z24. 8193 F1000
N140 G1 X483. 122 Y10. 5785 Z24. 8193 F4000
N145 G1 X478. 2798 Y1. 7893 Z16. 8193 F1000
N150 G1 X70. 8202 Y226. 2711 Z16. 8193 F4000
N155 G1 X65. 3727 Y216. 3832 Z7. 8193 F1000
N160 G1 X472. 8323 Y- 8. 0985 Z7. 8193 F4000
N165 G1 X501. 8857 Y44. 6367 Z55. 8193 F4000
N170 G0 X513. 4487 Y- 2. 6386 Z42. 8219 A90 B31. 1856
N175 G1 X494. 685 Y- 2. 6386 Z11. 8219 F1000
N180 G1 X494. 685 Y1306. 5286 Z11. 8219 F4000
N185 G1 X489. 8428 Y1306. 5286 Z3. 8219 F1000
N190 G1 X489. 8428 Y- 2. 6386 Z3. 8219 F4000
N195 G1 X484. 3953 Y- 2. 6386 Z- 5. 1781 F1000
N200 G1 X484. 3953 Y1306. 5286 Z- 5. 1781 F4000
N205 G1 X513. 4487 Y1306. 5286 Z42. 8219 F4000
N210 ( Cont our c ut of par t number : 12: 2)
N215 G0 X460. 9592 Y1759. 0555 Z56. 8654 A- 18. 414 B62. 4414
N220 G1 X479. 7229 Y1815. 4161 Z25. 8654 F1000
N225 G1 X72. 2632 Y1951. 068 Z25. 8654 F4000
N230 G1 X77. 1055 Y1965. 6127 Z17. 8654 F1000
N235 G1 X484. 5651 Y1829. 9608 Z17. 8654 F4000
N240 G1 X490. 0126 Y1846. 3236 Z8. 8654 F1000
N245 G1 X82. 553 Y1981. 9755 Z8. 8654 F4000
N250 G1 X53. 4996 Y1894. 7074 Z56. 8654 F4000
N255 G0 X43. 4832 Y1977. 5858 Z42. 8219 A90 B- 31. 1856
N260 G1 X62. 2469 Y1977. 5858 Z11. 8219 F1000
N265 G1 X62. 2469 Y1099. 8064 Z11. 8219 F4000
N270 G1 X67. 0891 Y1099. 8064 Z3. 8219 F1000
N275 G1 X67. 0891 Y1977. 5858 Z3. 8219 F4000
N280 G1 X72. 5366 Y1977. 5858 Z- 5. 1781 F1000
N285 G1 X72. 5366 Y1099. 8064 Z- 5. 1781 F4000
N290 G1 X43. 4832 Y1099. 8064 Z42. 8219 F4000
N295 G0 X56. 1307 Y1134. 1823 Z55. 1753 A35. 984 B- 45. 851
N300 G1 X74. 8943 Y1108. 3412 Z24. 1753 F1000
N305 G1 X482. 354 Y1404. 2044 Z24. 1753 F4000
N310 G1 X487. 1962 Y1397. 5358 Z16. 1753 F1000
N315 G1 X79. 7366 Y1101. 6725 Z16. 1753 F4000
N320 G1 X85. 1841 Y1094. 1703 Z7. 1753 F1000
N325 G1 X492. 6437 Y1390. 0335 Z7. 1753 F4000
N330 G1 X463. 5903 Y1430. 0455 Z55. 1753 F4000
N335 G0 X468. 0528 Y1395. 6697 Z53. 1781 A90 B- 31. 1856
N340 G1 X486. 8164 Y1395. 6697 Z22. 1781 F1000
Page 1
11:4
b) tool path
d) milling
c) machine code
f) assembly
216
9. PLYWOOD PROTOTYPE 02
9.4. Discussion
The construction of the prototype showed the ability of the form generation method
to react to precise formal and fabrication conditions.
Even though the form of the prototype is unconventional and surprising, it does not
seem arbitrary.
The spectator can perceive that an inner logic underlies the geometry
9.4. DISCUSSION
217
CHAPTER 10
Russel Lovrige
Lov08].
course was Material Logic. Starting from a construction material, the students had to
investigate the design parameters dictated by the material.
students had to examine were Alucobond composite panels. The brief for the nal design
of the workshop was to build a simple pavilion out of Alucobond panels.
Alucobond is a facade sheet material composed of two thin sheets of aluminum and an
inner core of PE plastic with a total material thickness of 4mm. Thin aluminum sheets
are very ductile and can be easily deformed. It is the combination with the core that gives
the plates a remarkable stiness while having a very light weight.
The idea to use Alucobond panels and directly fold them like paper folding seemed
very natural. The goal of the tests was to investigate if folding at this scale is possible and
under which conditions.
220
10.2. Fabrication
We used two dierent geometries for the tests:
(1) A very simple geometry with parallel folds. The regular corrugation prole had
constant amplitude and inclination angle, with three concave and two convex
main-folds. The convex cross section prole had three edges. The 18 quadrangular
faces have an average size of
1800 cm2
(2) The second geometry was more complex in order to show the limits of folding
Alucobond plates (see gure 10.3.1). The corrugation prole of the parallel mainfolds had constant amplitude but unequal inclination angles. The main diculty
was given by the cross section prole. It describes an S-curve and has convex and
concave curvature.
amplitude of the corrugation prole which means that the geometry has mainly
six-edge vertices. The number of faces is much higher than in the rst geometry
and size of the faces smaller.
110
550 cm2 .
The geometry was designed in 3-dimensional space and then developed as a plane surface
whose size was adapted to the Alucobond panels (2500
1250 mm).
To be able to fold
the panels, they were carved with a conical tool which removed the outer aluminum sheet
and the core material along the fold edges. The drawing of the developed surface and the
indication of the carving depth were translated to a machine code with CAM software.
The aluminum panels were xed with tape to the machine table to be milled.
The rst geometry was easy to fold with two persons. As in paper folding the parallel
folds were folded rst. To bend the folds, the convex folds were supported with a timber
block near the vertex and reversed by pushing down between the two side-folds. To avoid
crumpling the vertices they were cut out with a small hole.
The second geometry was more dicult to fold mainly due to the size of the faces. One
main-fold broke because of the multiple inversions. Indeed at each bending point the fold
is reversed from concave to convex and the material becomes more brittle in the fold edge.
This time we didn't cut out the vertices . We were surprised that even six-edge vertices
could be folded properly.
10.3. Discussion
The test showed that Alucobond panels could be folded and used for the geometries
we design.
For reasonable face sizes, the folding is easy and the vertices can be folded
properly without breaking or crumpling. Even six-edge vertices can be folded properly.
This opens new perspectives for the form generation method we developed. Applications in interior design, furniture design and facade cladding can be foreseen. It would be
very interesting to test curved folds with Alucobond plates.
10.3. DISCUSSION
221
10.4. Conclusions
Folded plate structures dene structure, space and envelope in a single surface. The
separation between engineering and architecture does not apply, folded plate structures
are both, structure and space.
Hexagonal pattern
Herringbone pattern
Diagonal pattern
simply-corrugated surface
Oblique folds
The folds are not parallel. The general shapes are straight surfaces, cylinder
prole varies but the inclination angle of its faces stays constant.
reverse folds.
xz
prole.
cross section
It denes the bending angle of the reverse folds. The reection planes are given by
xz
and
the inclination of the corrugation prole edges dene whether the geometry is completely
foldable or not:
Parallel
xz
Oblique
corrugation prole
cross section prole
10.4. CONCLUSIONS
225
The cross section prole allows design of the general shape of the folded plate geometry.
The general shape can be locally modied by the shape of the corrugation prole. The
folded plate geometry becomes helical if the simply-corrugated surface is placed obliquely
to the frontal projection plane
xz
The combination of the two proles can generate a great variety of forms.
The orientation of the cross section prole edges, determines the pattern type.
We
corrugation prole corresponds to the maximal amplitude of the cross section prole, fouredge vertices become six-edge vertices, and quadrangular faces become triangular.
We propose a method to control the cross section prole amplitude by using the incircle for convex polygonal cross section proles, and the ex-circle for zig zag cross section
proles.
This enables design of cross section proles with constant amplitude and thus
the bending angles, and therefore the general form, changes during the deployment of the
surface. By means of the cross section prole, the mid-line of the general shape, irregular
and oblique corrugated surfaces can be directly folded in space into their nal position.
This allows generatation of geometries which cannot be created by intuitive paper folding,
because they are not completely foldable.
1
The diagonal pattern can be considered as a special case of the hexagonal pattern where a simplycorrugated surface is placed oblique to the frontal projection plane xz . However this method only allows
representation of diagonal patterns where the diagonals are continuous straight lines.
226
Due to the reduction to two sets of parameters, the folded plate geometries can be
rapidly generated and modied. A great variety of forms can be generated. General shape
and corrugation can be adapted to specic conditions of a project. For example, amplitude
of corrugation can be increased at the edge to reinforce the border of folded plate structures.
This variability is very attractive because it allows the engineer as well as the architect to
act on project specic conditions by modifying the parameters of the folded plate structure
without alerting its expressive character.
We showed the consequences of specic parameter variations and their limits.
This
allows the designer to be conscious about the implications of certain decisions in the design
process right from the beginning.
The proposed design method can be applied in any 3D CAD software.
The reverse
side of the simplicity and variability of this method is that the general form is limited to
cylinder surfaces. Geometries based on multiple patches can create doubly-curved surfaces,
but they are less easy to handle and to modify.
The construction of physical models and prototypes was of great importance for the
comprehension of the proposed geometries. Building the geometries generated in 3D software, with timber panels, facilitated the verication of their the exactitude and gave us
awareness of problems we did not suspect. Particularly, questions about the geometry of
the joints between the plates became obvious.
The feasibility of folded plate structures with timber panels based on the proposed
methods has been shown.
The connections
between the panels are quite exible, which helps assmbly and indicates that it seems
reasonable to consider them as hinges for structural calculations.
10.5. Outlook
In further research we aim to implement the method of generating folded plate structures with a corrugation prole and a cross section prole in parametric software. This
would accelerate the design process and improve its handling. The implementation in a
parametric software would also open up the possibility of a connection with calculation
software in order to optimize the structural behavior of folded plate structures. For folded
plate structures with triangular faces, a parametric representation could also allow us to
deform the general shape, similar to the deformations that are possible with folded paper
models.
The currently proposed structures are single patch geometries.
The combination of
multiple patches has to be investigated in order to create doubly-curved surfaces. Particularly the methods proposed by
Delarue [Dea93].
It would be interesting to
10.5. OUTLOOK
227
The proposed method can generate curved folds. It would be interesting to investigate
the construction of curved folds made with a series of vertical planks, joined with linear
connectors or glued together.
The comparison between the deformation of one prototype with structural calculations
showed that the simulation of their structural behavior has to be improved.
The load
test also showed the importance of the connections which have to be examined carefully
for further realizations. The results of the load test engaged new engineering research for
We are convinced that full scale folded plate structures with timber panels are feasible.
Future projects will contribute to the constructive development of folded plate structures
(see appendix chapter 12). In particular the joints between the panels, the integration of
thermal insulation, and the exterior cladding, have to be developed in relation with specic
projects and in collaboration with engineers and the involved craftsmen.
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[Sed75a] V. Sedlak. Folded Surface Structures. PhD thesis, University of Surrey, departement of civil
engineering, Surrey, 1975.
[Sed75b] V. Sedlak. Paperboard Structures. In Proc 2nd Int Conf on Space Structures Univ of Surrey,
pages pp780793, 1975.
[SF00]
A. Sogame and H. Furuya. Conceptual study on cylindrical deployable space structures. In
S Pellegrino and S D Guest, editors, IUTAM IASS Symposium on deployable structures: Theory
and applications, pages 383392, 2000.
[Sie60]
C. Siegel. Strukturformen der modernen Architektur. Calwey, Mnchen, 1960.
[SS01]
A. Sogame and J. Saito. Deployable Structure, 2001.
[Sto09]
I. Stotz. Iterative Geometric Design for Architecture. PhD thesis, EPFL, ENAC, IBOIS, Lausanne, 2009.
[Tac09]
T. Tachi. Generalization of Rigid Foldable Quadrilateral Mesh Origami. In Proceedings of the
internaltional Association for Shell and Spatial Structures (IASS) Symposium 2009, pages 2287
2294, 2009.
[Ton91]
O. L. Tonon. Geometry of spatial folded form. International Journal of Space Structures,
6(3):227240, 1991.
[Ton93]
O. L. Tonon. Geometry of the spatial folded form. In Space structures 4, page 20242052. Thomas
Telford, London, 1993.
[Tor61]
E. Torroja. Die Logik der Form. Callwey, Mnchen, 1961.
[Tre08]
J.-C. Trebbi. l'art du pli. Editions Alternatives, Paris, 2008.
[Vas05]
N. Vasseur. Les Plis. Seuil, Paris, 2005.
[VlD56]
E. Viollet-le Duc. Dictionnaire raisonn de l'architecture franaise du XIe au XVIe sicle, 1856.
[Voi07]
P. Voigt. Die Pionierphase des Bauens mit glasfaserverstrkten Kunststoen (GFK) 1942 bis
1980. PhD thesis, Bauhaus Universitt Weimar Fakultt Gestaltung, 2007.
[Wal09]
Walsermuseum. St.Anna Kapelle, Faschinajoch, 2009.
[YK03]
Z. You and K. Kuribayashi. A Novel Origami Stent. In Summer Bioengineering Conference,
pages 02570258, Florida, 2003.
[Zei93]
F. Zeier. Papier, Versuche zwischen Geometrie und Spiel. Haupt, Bern, 1993.
[Zod73]
Zodiac. Piano. Zodiac Light weight structures, 22:130131, 1973.
Appendix
CHAPTER 11
236
Figure 11.0.2. Three folded plate geometries with identical general shape,
a S-curve. The amplitude is varies: The smaller the amplitude, the closer
the shape becomes to the S-curve
a)
z
y
z
x
b)
z
y
x
y
x
z
x
xz .
237
238
z
y
z
x
plane
xz
there is a
close relationship to the zig-zag cross section prole. Such a geometry can be decomposed
in three strips following three directions. The projection of the mid-line of one strip (green)
corresponds to a convex polygonal cross section prole. The projection of the mid-line of
the two other strips (red and blue) corresponds to a zig-zag polygonal cross section prole.
In gure 11.0.3 a) The green strip is parallel to the frontal plane
to a convex polygonal cross section prole.
xz
and corresponds
zig-zag cross section prole and are oblique to the frontal plane
In gure 11.0.3 b) all strips are oblique to the frontal plane
xz .
xz .
In gure 11.0.4 the green strip (convex polygonal cross section prole) is oblique to the
frontal plane
xz
and so is the blue strip (zig-zag cross section prole). The red stripe is
xz
For convex polygonal cross section proles with constant bending angle
it is possible
to design oblique folds with the edge of the folded plate geometry parallel to the frontal
plane
xz .
xz
can be determined by designing a single strip of related the zig-zag cross section prole.
a)
x
b)
y
x
with a convex polygonal cross section prole and a corrugation prole with
regular inclination angles.
239
240
a)
x
b)
y
x
z
x
y
Figure 11.0.6. Tennis hall: a) folded plate geometry with a convex polyg-
onal cross section prole and a corrugation prole with steeper inclination
angles on the border, in order to reinforce the edges of the folded plate
structure. b) folded plate geometry with a zig-zag cross section prole and
the same corrugation prole as gure 11.0.6a).
Figure 11.0.7. Tennis hall: exterior and interior perspective. The geom-
241
242
a)
A1
I1
b)
A2
A1
I1
I1
c)
A1
A1
I2
I1
A, inclination angle ,
A and the inclaination angle
angle
amplitude
stays constant.
I,
the
a)
b)
c)
243
244
Figure 11.0.10. Illustrations for dierent types of use with the geometry
of gure 11.0.9.
x
x
y
x developped
Figure 11.0.11. Folded plate geometry based on simply-corrugated sur-
245
246
y
x
y
x
y
x
Figure 11.0.13. Variations of herringbone patterns.
247
248
Figure 11.0.14. Herringbone pattern with edged and curved corrugation prole.
a)
b)
x
Figure 11.0.15. a) Study for a curved wall behind a reception desk of a
249
250
z
x
z
x
Figure 11.0.17. Cross section prole variations: Combination of convex
251
252
a)
b)
y
x developed
Figure 11.0.19. Convex polygonal cross section prole: the corrugation
amplitude is bigger than the maximal amplitude of the cross section prole
(see section 6.3.1.5).
253
254
Figure 11.0.21. Studies for a gymnasium, version a): The pattern is com-
255
256
257
z
x
y
z
x
z
x
y
x developed
Figure 11.0.23. Multi-patch geometries based on torus surfaces (herring-
bone pattern).
258
a)
z
x
b)
z
x
y
Figure 11.0.24. Multi-patch geometries: a) Torus surface (hexagonal pat-
z
x
y
z
x
y
z
y
x
259
260
zy
x
y x
z
x
y
z
x cross section profile
z
y corrugation profile
Figure 11.0.26. Example of a geometry with asymmetric corrugation
where the shift of the main-fold edge in the oset surface results in an
interesting tectonic.
CHAPTER 12
a partner on an unexpected side: the deaconess's of St.Loup. In spring 2007 they organized a competition to transform and renovate their nunnery. The team
Localarchitecture
important transformations to the chapel which meant that the deaconesses needed a temporary place for worship during the building work which was expected to last 18 months
[
BW08, BW09].
a)
b)
c)
Figure 12.1.1. a) Paper folding of the chapel b) plan of the Saint chapel
Paris [
262
How to reconcile the claim for a pragmatic and reasonably priced solution to be designed and built in very short time, with the exceptional spatial and symbolic quality
required for a place of worship?
Particularly interested and experienced in timber construction,
Localarchitecture
pro-
posed a collaboration with the laboratory for timber construction IBOIS of EPFL and its
start up company
Shel.
panels, seemed particularly adapted to achieve high architectural quality, rapid execution
and reasonable costs. Already the very rst paper models convinced the sister community
of the appropriateness of such a solution.
The form should express a certain simplicity and self evidence, be economic and
had to be rapidly assembled.
The form should recall some characteristics of a church space; a simple rounded
nave. To do so, the corrugation mid-line (blue) is slightly bent. This compresses
the folded surface and the space of the nave raises up in direction of the chancel
(see 12.2.1). The progressive transition from the horizontal to the vertical gives
the room a clear focus and meaning: it evokes the transition from an earthbound,
human condition to a spiritual quest. On the exterior the rst crease denes an
entry porch and the rising tip on the other end recalls a small belfry (see gure
12.1.1c)).
The geometry of the chapel should dene simultaneously dene space, enclosure
and structure: a series of parallel folds give the surface the necessary depth to be
self supporting (see gure 12.2.1b)). As in traditional churches the structure has
an important presence in space. The rhythm of the columns is taken up by the
folds and organizes the nave (see gure 12.1.1b)).
263
In a second phase the parallel corrugation was modied and became oblique.
Therefore the method of design oblique folds with a ruled surface was used (see
section 4.3.2) The convex folds are now oblique whereas the concave folds stay
parallel to each other: wall and roof are modulated by deep and small folds and
the roof creases become transversely inclined (see gure 12.2.1c)).
The sloped
a)
b)
c)
Figure 12.2.1. Geometry of the chapel:
264
roof creases allow the rain water to be evacuated. The irregular inclination of the
surfaces improves the acoustics and the lighting of the chapel. Light entering from
the gable facades reects o the oblique surfaces and traces a slightly irregular
and subtle succession of shadows on the timber plates.
structure developed in the form-nding process, the digital le from the modeling tools
was directly imported into the calculation program Diamond (Buildsoft). The supporting
structure needed to be constructed with cross-laminated timber panels with thicknesses of
40 mm
60 mm
introduced into the calculation software. The structural analysis conrmed the thickness
of the plates and the poly-surface in the modeling tool could be oset.
In the calculation the edges of the folds were simulated as hinges. Despite the rotational freedom of all joints the overall stiness of the structure is given by the specic
spatial arrangement of the elements.
perpendicular to the edge) were blocked in the model. In reality bending moments occur
along the folds, since the panels are connected with thin steel plates.
Depending on the rotation direction of the moments, varying lever arms occur caused
by the unilateral connection of the timber panels with steel plates. However these local
bending moments were neglected in this model. From the static software was determined
both the deformations, and the internal forces. The 60 mm thick plates of the roof bear
more than about
9m span,
1/150.
The enormous
eciency of folded plate structures is evident by this very high slenderness. The point with
the largest deformation of the entire structure is located on the outer edge of the folded
plate structure directly above the entrance. Since this edge is not supported by further
folds, the edge is free and therefore not stiened.
12.3.2. Oset.
cause of the oblique folds and the changing inclination angles of the faces, but also because
of the dierent thicknesses of horizontal and the vertical plates. The small number of faces
(42) made it more rational to design the oset by hand than to develop a script adapted
to this particular conguration.
strongly vary and as a consequence the main-fold edges of the oset surfaces are shifted
265
as described in 7.2.3. Even though locally the shift is important, it doesn't deteriorate the
perception of the general shape of the chapel.
1700.00
3400.00
Type 5
pe
Ty
axe du pli
3000.00
1200.00
1800.00
pe
2400.00
Ty
axe du pli
1700.00
1600.00
3200.00
axe du pli
Type 3
2400.00
1200.00 1200.00
Type 1
Type 2
1200.00 1200.00
Type 4
1200.00 T3
1200.00 T3
Type 2
Type 4
1200.00 T3
Type 1
Type 4
1600.00
Type 1
Type 2
Type 1
Type 2
1200.00 T3
Type 1
Type 2
Type 1
Type 2
Type 2
Type 4
1200.00 T3
Type 2
Type 4
1200.00 T3
Type 1
1200.00 T3
Type 2
Type 1
Type 2
Type 1
Type 2
Type 1
Type 2
Type 2
Type 4
1200.00 T3
Type 2
Type 1
Type 2
1200.00 T3
Type 2
Type 4
1200.00 T3
Type 2
Type 1
1199.98 T3
1200.00 T3
(ECH.: 1/10)
Type 2
1200.00 T3 T2 1200.00 T3
Type 2
1200.00 T3
1200.00 T3
Type 1
Type de tle
(ECH.: 1/100)
1200.00 T3
1199.99 T3
Faade
pe
5
1200.00 T3
Ty
1200.00 T3
Toiture
1200.00 T3
1199.99 T3
pe
1200.00 T3
Ty
Type 1
Faade
1200.00 T3
Type 1
axe du pli
the joints
axe du pli
266
12.3.3. Fabrication.
ing the oor panels, the cladding panels, the support beams and the protecting battens of
the gable facades. The geometry was transferred to the carpenter's software who transferred it without modications to the panel fabricator.
sidered the panel size of the fabricator. Furthermore all concave folds are parallel, which
allows one to package two adjoining panels in a rectangular form that doesn't exceed the
panel size of the fabricator (see gure 12.3.2).
12.3.4. Construction.
on a stabilized ground.
anchor the building to the ground. A grid of longitudinal timber girders supports the oor
panels (CLT
40 mm
) The edge girders follow the zig-zag form of the corrugation. They
are connected with the oor panels and the bricks by steel anchors. The
panels are screwed to the edge girders.
40 mm
thick wall
with the inclination angle of the wall panels. The upper edge of the wall panels supports
the
2 mm
thick metal plates. They are standard timber connections, plates with regular holes for
nails or screws, that are folded with the correct inclination angle. The width of the plates
varies in function of the curvature of the folds in order to guarantee a correct distance
of the screws to the edge of the timber panels.
those for concave folds. The crease of the side fold plates is asymmetric because of the
superposition of the roof panels to the wall panels. Screws connect steel plates and timber
12864
8601
8698
2250
2809
2969
6849
10119
2250
2715
2906
10419
9366
11030
2250
2713
2789
9606
8442
11744
10860
2250
2778
2904
10409
8397
2250
2818
2927
12134
8166
12312
2250
2828
2961
11087
12181
11725
Figure 12.3.2. Developed surface and panel layout for the fabrication
2753
2967
1736
13343
267
can be distributed along the whole fold edge. As a consequence, the stress can be spread
over a large number of connectors instead of being concentrated in a single point as in
linear frameworks. The inside of the structure is free from connectors. The panel surface
is visible and not treated: Structure, form and internal lining are constituted of a single
element.
The structure is covered by a roof membrane that protects the structure against rain
and humidity. The exterior boarding is made of
18 mm
to vertical battens. The joints between the boarding panels are open and the rain water
is drained on the roof membrane along the slope of the structural panels. The boarding
panels are coated with a copper gray glaze in order to prevent an unequal graying.
12.3.5. Assembly.
fabricated and milled in the factory and delivered to the construction site with their nal
shape.
To manipulate the panels they were equipped with threaded bolts which allow
xation of a steel hanger. First, three wall panels were xed to the edge girders on each
side.
formed the rst crease they started to stabilize each other. They were adjusted and held in
position with the help of telescopic bars. Secondly, the roof panels were xed onto the wall
panels. The steel plates for the connections were xed to the panels on the ground. This
helped to position the panels because they could be leaned onto the preceding panels along
the main-fold. Again the adjustment of the panels was eected with telescopic supporting
bars.
The fact that the concave roof creases and the convex wall creases form parallel
planes perpendicular to the oor, served as a guide and helped for the adjustment of the
panels.
Even though this was the carpenters rst experience with cross-laminated timber panels
and this type of structure the assembly got o perfectly well, was precise, and achieved
completion within ten days.
to answer to three criteria: procure a good natural lighting, guarantee a certain intimacy
and create contact with the natural environment. The timber framework is reminiscent
of a stained-glass window. The inside end wall is covered with corrugated polycarbonate
panels which have an excellent light transmission factor but slightly blur the outside view
because of their structure. A wind protection textile on the outside acts as a lter: during
the day it protects the inside of the chapel from the outside view, in the night the eect is
reversed and like a Chinese lantern, the chapel, signals its presence by a warm light.
Nails could have been used as connectors but, because the chapel is a temporary building, the possibility
to dismantle and rebuild it in an other place was foreseen. Screws were used to make the dismantling
easier.
268
longitudinal section
transversal section
(ECH.: 1/25)
(ECH.: 1/25)
Planche de protection
| avec goutte pendante
Arrtes latrales
Tles type bmf, plis
ep 3mm
largeur 300mm
en continue sur l'arrte
175 clous par ml
tanchit
panneau bois contrecoll 60mm
face exteriure fintion industrielle
Face interieure finition B
Arrtes en toiture V
Tles type bmf, plis
ep 3mm et 2 mm
largeur 240mm
en continue sur l'arrte
150 clous par ml
Arrtes latrales
Tles type bmf, plis
ep 3mm, largeur 300mm
en continue sur l'arrte
175 clous par ml
arrtes verticales ^
Tles type bmf, plis
ep 2 mm, largeur 320mm
en continue sur l'arrte
arrtes verticales V
150 clous par ml
Tles type bmf, plis
ep 2 mm et 3mm, largeur 240mm
en continue sur l'arrte
150 clous par ml
arrtes verticales ^
Tles type bmf, plis
ep 2 mm, largeur 320mm
en continue sur l'arrte
150 clous par ml
tanchit
Rampe d'accs:
panneau bois contrecoll 40mm
face suprieure finition B, stri
Face infrieure finition industrielle
sur longrines en bois equarri 80x120
plancher auvent
panneau bois contrecoll 40mm
face suprieure finition B, stri
Face infrieure finition industrielle
sur longrines en bois equarri
80x120
bo is e qu arri su rp lo t d e
b to n
tanchit
panneau bois contrecoll 60mm
face exteriure fintion industrielle
Face interieure finition B
Arrtes en toiture ^
Tles type bmf, plis
ep 2 m, largeur 320mm
en continue sur l'arrte
150 clous par ml
arrtes verticales V
Tles type bmf, plis
ep 2 mm et 3mm, largeur 240mm
en continue sur l'arrte
150 clous par ml
Planche de protection
avec goutte pendante
Planche de protection
avec goutte pendante
269
270
12.4. Discussion
The project for the chapel of St.Loup shows a successful integration of architectural,
engineering, and production constraints in the design process. This conrms the interest
for folded plate structures with cross laminated timber panels and of the proposed design
method. The quality of the project is its ability to generate by a precise regulation of its
geometry relevant and synthetic answers to various constraints. It proposes
The materialization with cross-laminated timber panels resolves spatial enclosure, structure
and interior nish with a single element.
The design process was very fast and the design team and the client quickly agreed to
the proposed architectural and structural form. It is interesting to note that even though
we were searching for a close relationship to a traditional religious space, the form came out
of the inherent logic of the folding process: by making the space more narrow in direction of
the chancel it automatically grows vertically. The form of the space and the architectural
elements it evokes are proposed by the folding process itself and only have to be discovered
by the project designers in order to comprehend their signicance. It somehow reverses the
traditional design process
: it is not the intention that shapes the form, but the inherent
logic of the design method that suggests, during the design process, the intention.
The
relationship between intention and form gets blurred, the architect doesn't just imagine
the form but also discovers form and signicance by staying receptive to the implicit rules
of the design method he uses.
The quick fabrication and assembly of the timber panels showed the eciency of working with methods that generate geometries with discrete elements, and allow a rapid transition from design to construction. The joints to assemble the panels are simple and can
be executed by any carpenter.
The chapel is very appreciated by the deaconesses but also by a large public of experts
and laymen. Its somehow strange but familiar form, the simplicity of its construction, its
materiality, transmit an atmosphere and beauty beyond the traditional aesthetic categories.
Finally we have to mention the pioneering spirit of all participants to the project, but
particularly the one of the deaconesses. Their openness and enthusiasm was most decisive
to the realization of the chapel.
12.4. DISCUSSION
Figure 12.4.1. The entry porch and the west facade (photos: F.Hatt)
271
272
Credits
Client:
Architecture:
Shel, Hani Buri, Yves Weinand, Architecture, Engineering and Production Design
Engineering:
Shel, Hani Buri, Yves Weinand, Architecture, Engineering and Production Design
Funding:
CREDITS
Figure 12.4.2. The Chinese lantern, light reection on walls and roof
273
CURRICULUM VITAE
275
Curriculum vitae
Hani Buri
Born in Bern, Switzerland, 27 Mai 1963
Married, two children
Education
2005-2009
2004
1991
1984
Professional experience
Shel , Hani Buri, Yves Weinand, Architecture, Engineering and Production Design
since 2005 Scientic collaborator, laboratory for timber constructions, IBOIS, EPFL
1993-2005
1991-1993
BMV architectes, Hani Buri, Olivier Morand, Nicolas Vaucher, architectes EPFL
Co-founder and partner of
Independent architect
Teaching
since 2006 Course instructor, timber construction course for architects and engineers,
EPFL
since 2006 Assistant, Atelier Weinand, EPFL
since 1995 Visiting critic, and lectures in dierent architecture classes, EPFL, EPFZ,
ESBA, IAUG
1994-1998
1993
1993
1992
Miscellaneous
languages
Fdration des Architectes Suisse, FAS, member of the committee, section Geneva
Fdration des associations d'architectes et d'ingnieurs de genve, fai, member of the
committee
Schweizerische Arbeitsgmeinschaft fr Holzforschung, SAH, member of the committee