ShapeToFabrication (STF)

Summary

The Shape to Fabrication (STF) conference in London gathered experts from various fields to discuss the latest developments in design, fabrication, and construction. Day one of the event featured several captivating presentations from leading companies like Heatherwick, Arup, Speckle, and Henning Larsen, covering topics ranging from performance-driven design tools to the integration of fabrication techniques in the design process. Attendees also had the chance to learn about innovative projects and future developments in Rhino and Grasshopper software, as well as explore the role of data in driving knowledge and better decision-making in the industry. Rhenso had the opportunity to present their #AdaptivePartsEnvironment, which generated significant interest from conference participants.

Thanks to organizers Paul Cowell and Harry Charrington for a fantastic event!

Day One

Session 1

Title: Workplace of the Future: Google Bay View using emergent technologies to enable innovative and sustainable design

Company: Heatherwick studio

?Presenters: Kyriakos Chatziparaskevas & Pablo Zamorano Mosnaim

In their presentation at the Shape to Fabrication conference, Kyriakos Chatziparaskevas and Pablo Zamorano from Heatherwick Studio shared their approach to the design and construction of Google's Bay View HQ in California. This innovative project is the largest LEED v4 BD+C: NC Platinum certified project in the world, and it heavily relies on computational tools to optimize various aspects, such as solar PV, water drainage, and user comfort.

The presenters discussed the importance of collaboration with contractors and detailing every aspect of the building to ensure sustainability. They also highlighted the optimization of the roof shape for solar energy production and effective water drainage to maximize water reuse. The building employs geothermal cooling and integrates several features aimed at enhancing user comfort while maintaining a sustainable design. This presentation showcased the power of using computational tools to create truly sustainable, high-performance buildings.

Title: Re-Imagining “Total Architecture” from the internet up.

Company: 奥雅纳

Presenter: Fernando Ruiz Barberán

?At the Shape to Fabrication conference, Fernando Ruiz from Arup presented on re-imagining "Total Architecture" in the context of modern digital tools and interoperability. He emphasized the shift from traditional document-centric workflows to data-centric ones and the importance of proactive multidisciplinary collaboration in successful projects.

Ruiz introduced Arup's in-house developed tool, "InForm," a design framework that allows for intuitive apps, data storage, and optimization through machine learning. He also discussed their next tool development, "TotalDesignAutomation," which aims to organize all in-house tools and integrate them with Speckle.

Speckle, as a solution for data-centric workflows, provides a single database and connectors to various tools, enabling seamless interoperability. Ruiz highlighted the need for data-based, rather than file-based, collaboration, as the team holding the file may not be best suited for optimization.

The future of BIM, according to Ruiz, should focus on models of agreed design principles and pre-coordinated complexity. His vision for the ideal platform is an "AppStore"-like environment with easy-to-use tools that deliver visually appealing insights.

Title: Innovation towards Data-Centricity

Companies: Speckle & Henning Larsen

Presenters: Jonathon Broughton & David Fink

David Fink from Henning Larsen and Jonathan Broughton from Speckle presented on innovation towards data-centricity in the architecture and construction industry. They discussed the challenges of dealing with data and questioned whether using files was the best method.?

Fink highlighted how Henning Larsen, a global studio with 750 employees, is using Speckle to enable multidisciplinary teams and collaborators to work together in an agile and dynamic way. They are implementing a central data hub that connects authoring tools, cloud solutions, stakeholders, and objects to facilitate data sharing and visualization.

Speckle has been instrumental in converting RhinoEdgeModels into landscape models fluently, as well as enabling the immediate evaluation of carbon impact with "Carbon Goggles." Henning Larsen also utilizes their sustainability tools, like Fenix, to assess the environmental impact of their designs and create "green scenarios."

The presentation emphasized the potential benefits of moving towards data-centricity in the industry, highlighting how Speckle and data-driven tools can transform workflows and lead to better-informed designs.

Panel Discussion 1

The panel discussion raised questions on the integration of design principles, the impact of fabricators on design, data ownership, and the transition towards drawing-less processes. The participants agreed that interoperability and data-centric workflows are essential for the future of architecture, but also acknowledged the need for a change in mindset and further legal clarification on data ownership. The idea of "Opportunity Detection" was brought up as a way to leverage data for better decision-making and knowledge in the industry.?

Fernando Ruiz was asked about the responsibility for creating design principles, whether it lies with architects, engineers, or fabricators. He highlighted that while a comprehensive solution has yet to be found, collaboration is crucial in achieving the best results. He compared the process to Formula One car design, where multiple teams with varying rules and constraints collaborate to create the best vehicle possible.

The Google Bay View team discussed the influence of fabricators on design and the overall process. They explained that architects would ideally prefer clean, seamlessly welded steel structures. However, due to practical constraints, bolted connections are used for increased efficiency. The decision to use bolts instead of welding offers an opportunity to celebrate bolt design visually.

The team also addressed the benefits of shared infrastructure for future projects. They mentioned Speckle as an excellent tool for facilitating collaboration in multi-party projects, providing an external data pool for seamless data exchange between architects and other stakeholders. The online data pool can be reused in future projects, saving time and effort. However, the question of data ownership and legal issues remain unresolved.

David Fink spoke about the potential of data-driven design and data inputs to generate "knowledge." He emphasized that making information visible enables learning from past decisions and improving over time. Integrating machine learning into this process is an internal consideration.

Lastly, Arup and Henning Larsen representatives were asked about the possibility of eliminating drawing sets altogether. They warned of the risk of sacrificing quality for speed and suggested that a change in mindset is needed. All parties should agree on a less drawing-intensive process from the beginning, though this shift may take longer than anticipated to become the norm.

Session 2

Title: DesignOps: Performance Drive design pipelines

Company: Foster + Partners

Presenters: Martha Tsigkari , Marcin Kosicki , Sherif Tarabishy , Oscar Borgstr?m

At the Shape to Fabrication conference, Martha Tsigkari, Marcin Kosicki, Sherif Tarabishy, and Oscar Borgstrom from Foster + Partners presented on DesignOps and performance-driven design. They discussed the challenges of speed and accuracy in interactive design interfaces, high-performance distributed computing, and custom analytical software.

Foster + Partners' Applied R+D team has developed several internal tools to address these challenges, including Thalia (an early-stage performance analysis tool) and Cyclops (a real-time feedback tool for analysis). Cyclops runs analysis on GPUs instead of CPUs and has Grasshopper components, making it compatible with other tools like APE. It can handle various environmental and spatial analyses, including daylight factor analysis, and has an integrated automated report generator.

Another tool, HYDRA, is an optimization system that uses distributed computing to harness idle machines in the office for solving large optimization tasks. This technology is based on the film industry and enables Foster + Partners to run optimization on large urban models much faster than traditional methods. HYDRA has also been integrated with CityEngine, and its data can be visualized in a web-based interface or fed into machine learning algorithms for predictive analysis.

The goal of DesignOps is to empower users, democratize knowledge, and improve business decisions by bringing tools, technology, and people together to create real-time feedback and improve design outcomes.

Title: Beyond the code: A Quest in validating structural design driven by fabrication

Company: YIP (Yes it’s possible)

Presenter: Manja van de Worp

The talk focused on the opportunities and challenges of engineering solutions driven by fabrication that fall outside the standard code of practice. As new technologies in materials, fabrication, and construction emerge to reduce carbon impact, non-standard structural elements are becoming more common.

To validate these non-standard solutions, they need to be classified and integrated into existing codes. Testing can help understand the compound capacity of the structure, as well as its failure mechanisms, to achieve a new approval and reduce carbon in new constructs. The presentation also explored how to integrate fabrication techniques and knowledge into design solutions, such as accounting for the transition from wet to dry materials (shrinkage, cracking) and engineering comfort for flexible objects like chairs.

The talk emphasized the importance of sharing and consolidating engineers' links to fabrication-driven design projects that require unique performance specifications.

Session 3

Title: Sugar Slab – Upcycling industrial waste into construction material for interlocking kit-of-parts systems designed for disassembly and reuse

Company: Grimshaw Design Technology

Presenter: Elena Shilova

The project aims to use bagasse, a by-product of sugar production, as the core resource for a novel material system called Sugarcrete. Sugarcrete is four times lighter than traditional brick and has only 15-20% of its carbon footprint.

Through a collaboration between Grimshaw, UEL, and Tate and Lyle Sugars, Sugarcrete has the potential to replace the traditional brick industry entirely, saving 1.08 billion tonnes of CO2 and 3% of the global CO2 production if just 30% of the world's bagasse production is utilized. The material is insulating, fire-resistant, easy to use with unskilled labor, and has a reduced supply chain due to its simple composition.

The Sugar Slab system is an interlocking kit-of-parts that has been tested with Sugarcrete in 1:1 scale. It enables large span construction from small discrete components without mortar and performs superior to conventional monolithic assembly due to reciprocity and distributed force networks. The project integrates material programming, geometrical design, and advanced fabrication within one continuous toolchain.

As a result, Sugar Slab presents a material-efficient, falsework-free, reconfigurable kit-of-parts system designed for disassembly and reuse, providing a sustainable alternative towards decarbonizing the construction industry. During the presentation, an audience member accidentally dropped a 3D-printed mockup of the system, highlighting its easy reassembly and causing laughter among the audience.

Title: Adaptive Digital-Physical Workflows in Wood

Company: Xylotech

Presenter: Martin Self

Xylotek specializes in the technical design, fabrication, and construction of non-standard timber structures, emphasizing that using wood is fundamental to making buildings more sustainable.

The distribution of different trees and their complex process flows make working with wood a challenging task. The presentation discussed how to create material-digital workflows to allow for the best exploitation of wood's properties. Through a series of case-study projects, Martin showcased stunning structures like Sherborne Gridshell and Abba Voyage Arena. He also explained how to create digital workflows that bridge the gap between design and manufacturers, optimizing wood's strengths and enabling the construction of complex timber structures by a team of around 35 people.

Title: Democratising Offsite, Digitising OnSite Construction

Company: The Circular Factory

Presenter: Alicia Nahmad, PhD

Unfortunately, this presentation was missed.

Title: 3D Printing as a means of improving sporting performance

Company: METRON ADVANCED EQUIPMENT LIMITED

Presenter: Dimitris Katsanis

The presentation focused on 3D-metal printing and its applications in the cycling industry, where Metron has been involved since 1992.

3D printing is advantageous for situations with tight production timelines, complex geometries, or when traditional manufacturing processes are not suitable. It can be used for aerodynamic interventions, anatomic/ergonomic customizations, part integration, and weight reduction.

Dimitris discussed how 3D printing can be used to manufacture equipment for a wide range of sports, and how it is likely to grow more affordable over time as CFD, design, and printing technology develop. To achieve the versatility offered by 3D printing, products must be designed with the manufacturing process in mind.

The presentation highlighted the ways and methods used by METRON engineers to design components that have been used in several world records and gold medals in cycling events. This included using CFD analysis to optimize both the bike and the rider's performance.

Title: Technology Update Q&A

Company: Robert McNeel and Associates (TLM, Inc)

Presenter: Almost all Rhino Team ;)

Day one of the STF conference in London included a fascinating technology update and Q&A session from the Rhino team at McNeel. The team shared current news and future plans for Rhino and Grasshopper, as well as updates on development frameworks such as rhino3dm, Rhino.Compute, and Rhino.Inside. They also discussed the ongoing web technology projects that will enable these tools to be deployed anywhere, which could significantly impact office workflows.

Some of the exciting new features in Rhino 8 presented during the session included:

1. Expanded geometry types and tools: The team showcased new additions to SubD, Mesh tools, and Shrinkwrap, which allow for a more streamlined modeling process, particularly when working with 3D-printing models.
2. Improved drafting and illustration tools: Rhino 8 will offer features like Reflecting Ceiling Projection, tapered curves for display, and enhanced sectioning capabilities, making it a more powerful tool for creating 2D plans, sections, and elevations.
3. Enhanced integration between Rhino and Grasshopper: Grasshopper will now include components for hatch, dimensions, and blocks, as well as the ability to read and write 3DMs, enabling seamless collaboration between the two programs.
4. The future of visualization: Rhino 8 will feature the Cycles X Engine, native MAC hardware acceleration, PBR material support, and speed improvements for complex scenes.
5. Making Rhino available everywhere: Integration into programs like Tekla, XLS, Illustrator, and Revit, as well as the development of iRhino for iOS and iPadOS, will allow users to access Rhino on multiple platforms and devices.
6. Laying the foundation for emerging technologies: Rhino 8 will have a new code editor based on CPython 3, enabling the use of AI libraries and creating a more robust platform for future development.

Overall, the technology update from McNeel provided a comprehensive look at the exciting new features and capabilities in Rhino 8, showcasing the software's potential to revolutionize design, fabrication, and construction workflows.

Conclusion

The first day of STF showcased the potential of computational tools and data-centric approaches in transforming the architecture and construction industry. As we look forward to the second day of the conference, it's clear that these innovative methods will play a crucial role in shaping the future of sustainable design and efficient workflows in the field.

The first day of STF concluded with a delightful gathering at the nearby Beehive Pub, where Speckle graciously extended an invitation to attendees for beer and pizza, playfully embracing the developer stereotype. This social event provided a perfect conclusion to an incredible day of learning and networking, leaving everyone eager and excited for the upcoming experiences of day two.

Day Two

Session 1

Title: Role of Architects and Engineers in the Metaverse and its relevance to the AEC industry

Company: Zaha Hadid Architects & 奥雅纳 ?

Presenter: Henry David Louth & Conor Carson Black

In this presentation Henry David Louth from Zaha Hadid Architects and Conor Carson Black from Arup discussed the potential of the metaverse and spatial technology in the architecture, engineering, and construction (AEC) disciplines.

The metaverse, with its focus on user experience (UX), gamification, and social engagement, aligns well with the design ethos, goals, and technologies used in the AEC industry. The session outlined the role of AEC disciplines in serving and hosting various human interactions and activities, such as work, leisure, retail, and cultural experiences, through several use case study applications.

The research presented is motivated by the suitability of game technologies to negotiate consumer demand, stakeholder competing priorities, and democratize a digital property marketplace. The session outlined several concepts and application scenarios addressing problems, benefits, and best practices for design planning in web-based, real-time applications, including:

• Modular planning strategy for mass customization
• Continuity of digital toolchain end-to-end customer to supplier
• Geometry optimization for real-time applications
• Content creation strategy and workflows
• Data-enriched objects for augmented reality and mixed reality applications
• AI tools and pipelines for geometry creation

Some projects discussed included the Beyabu Configurator, a virtual space for configuring architecture, making non-experts into experts by providing them with proper tools; and the LaLiga Sunlight Broadcast Planning Application, which helps determine the best camera placement in stadiums to minimize disturbing shadows or bright areas for optimal visibility. The session also touched upon developing strategies for property management within the metaverse and NFTism, a gallery that exhibits objects and space with an artist.

Title: New Adventures in Hi(Tech) – Low(tech) with Bamboo

Company: AKT II

Presenter: Edoardo Tibuzzi

Eduardo Tibuzzi from AKT II explored the use of bamboo, a renewable natural resource with high durability and sustainability, in architectural applications. The company's applied research team tested bamboo's usage in various challenging conditions, learning from the unpredictability of the low-tech approach, applying computational principles, and trialing digital methods to solve the challenges of structural connections.

The presentation highlighted the challenges with bamboo, such as high variability in size and shape, which require craftsmanship for "as found" construction. While there have been many impressive bamboo projects, there is a lack of studies on its capabilities.

One project discussed was in Bangladesh, which aimed to provide housing for people displaced by monsoon flooding using solely local materials. The team designed steel connectors and built a mockup to demonstrate the principle. However, they faced challenges with the weight, high costs, and weakness in one axis of the nodes.

The team then explored other node connections and bundling multiple bamboo sticks. They traveled to Bangladesh for hands-on experience and built a 1:1 example of the final shelter. The presentation also highlighted that not everything went perfectly and emphasized the importance of constant improvement and learning.

Overall, the presentation showcased the combination of high-tech digital design and fabrication methods with low-tech materials and installation techniques, demonstrating the potential of bamboo in architectural applications.

Title: On the way to Convergence

Company: Herzog & de Meuron

Presenter: Michael Drobnik & Vasilis Kalisperakis

Herzog & de Meuron's design process integrates hand drawings, physical models, and mock-ups with digital technologies through their multidisciplinary Design Technologies team. The presentation by Michael Drobnik and Vasilis Kalisperakis focused on the convergence of tools, cross-functional teams, and experimentation for an Integrated Design Experience.

Key points from the presentation:

1. The use of animations to tell stories and aid designers: The film about Poseidonos showcased coastal homes in Greece, using animations and music to create emotions and convey a sense of storytelling. The presentation also highlighted experiments with animating elements in architectural visualizations, such as trees, leaves, water, and camera movements.
2. Blurring the line between physical and digital: Model making plays a vital role in the design process, used not only for showcasing finished work but also for understanding construction principles. The presentation discussed combining physical models and animations to convey design ideas and spaces more effectively. During the COVID-19 pandemic, the use of Fologram AR with physical models allowed for additional information overlays, as demonstrated with a hospital project in Denmark.
3. The role of Digital Technologies within Herzog de Meuron: The presentation highlighted the importance of the Design Technologies team and their efforts to integrate both physical and digital tools in the design process to create a seamless experience.

Title: Maker and Material : Explorations in furniture, sculpture and Architecture

Company: Joseph Walsh Studio

Presenter: Joseph Walsh & Martin McGloin

Joseph Walsh Studio's presentation focused on the evolution of craft and its role in society throughout history. The studio is known for its distinctive forms and language, resulting from a designer-maker led approach. The talk reflected on the studio's maker-led design approach, showcasing their renowned projects, and discussing the potential to scale and apply this approach to different design vocabularies through collaboration.

Key points from the presentation:

1. Decoding Craftsmanship: The studio organized events to educate employees and later expanded to larger events, emphasizing the importance of craftsmanship in their work.
2. Stunning designs and design process: The presentation showcased impressive designs that highlighted a strong sense of material and beauty. However, there was limited information on how the physical and digital aspects were combined in their process.
3. A glimpse into digital integration: One pavilion project showcased the use of 3D scanning to adapt the wooden structure on top of massive stones without controlling their shape and placement.

Title: Realising complexity

Company: Foster + Partners

Presenter: Adam Davis , Khaled Elashry , Marios Tsiliakos

Foster + Partners' presentation showcased how their Applied R+D team is leading the shift to collaborative design systems, emphasizing the use of Grasshopper in innovative architectural projects. They highlighted the seamless experience of combining multiple designers, disciplines, and software for recent built works and projects on-site, including a mixed-use development in San Francisco, the Mobility Pavilion for the Dubai World Expo 2020, and the Lusail Towers in Qatar.

Key points from the presentation:

1. Workflow changes: They developed a tool that automatically converts 2D floor plans into 3D models, contrasting with the common practice of deriving 2D plans from 3D models in Revit.
2. Mobility Pavilion: They created design studies using Grasshopper by defining clear profile sections and profile axes, allowing for flexible and efficient design exploration.
3. Lusail Towers: The design evolved from initial tower concepts to twisted towers based on an elliptical shape that rotates and changes. This design was more structurally sound and cost-effective, leading to its acceptance. The team optimized panelization using self-optimization rules and focused on exchanging coordinates of points instead of breps or curves.
4. Emphasis on collaboration: The presentation highlighted the importance of collaboration in design, with parametric models built in Grasshopper serving as microservices for different stakeholders to work together effectively.

Title: Eliminating the Two-week Turnaround

Company: Ladybug Tools & Thornton Tomasetti

Presenter: Chris Mackey & Jeroen Janssen

Chris Mackey and Jeroen Janssen's presentation explored the "two-week turnaround" problem in the building industry and demonstrated how Pollination CAD plugins and the cloud platform can help overcome the challenges associated with energy modeling and building simulation. They showcased how Thornton Tomasetti applied these workflows to three active projects, enhancing collaboration between different disciplines.

Key points from the presentation:

1. Pollination: A suite of CAD & BIM plugins, cloud computing service, and collaboration platform designed to streamline workflows and enhance collaboration in the building industry.
2. Thornton Tomasetti case study: The Stockholm Central Station project involved extensive daylight studies, including shadow analysis, daylight availability, radiation on facades for PV potential, and outdoor comfort. The project's large scale presented a significant challenge.
3. Pollination Cloud: Users can create "recipes" on-premise and then connect to the Pollination Cloud using special components, enabling faster calculations and results delivered within minutes. Visualizations can be viewed in a web browser or exported as PDF reports.
4. Integration: The Pollination Rhino plugin shares the same interface as the web platform and works seamlessly with Revit, allowing for a consistent user experience across different applications.
5. Collaboration: The Pollination Platform offers apps available online and on computers, ensuring all team members have the latest version and eliminating the need for sharing multiple Grasshopper files with local variations.

Unfortunately we had to leave after this session to catch our flight back home - which we did but flight was cancelled... :(

Summary

Day 2 of the STF event showcased a diverse range of presentations, highlighting the various ways technology, collaboration, and innovative methodologies are transforming the AEC industry. From the potential of the metaverse to enhance user experience and collaboration to the exploration of low-tech materials like bamboo, presenters demonstrated the versatility of AEC disciplines in adapting to new challenges and opportunities.

Emphasis was placed on the integration of digital tools and traditional craftsmanship, illustrating the importance of balancing both in the design process. Projects presented displayed how architects and engineers utilize digital platforms to streamline communication, optimize designs, and improve efficiency while preserving the essence of craftsmanship and human touch.

Overall, the presentations on day two showcased the exciting advancements and possibilities in the AEC industry, emphasizing the role of technology, sustainability, and collaboration in shaping the future of design and construction.