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Metaplas: 3D-Printed Multi-Polymers
Project details
Programme
Research Cluster
RC8
Contemporary design-and-build methods are often missing a model that unifies design, materiality, structural requirements, and fabrication through digital tools. Metaplas, a comprehensive material system, was developed in response to this gap. The Metaplas material system can be fabricated ecologically and ethically and offers economic benefits through a decentralised system. Beginning with extensive material research, two recyclable thermoplastics were identified for their potential to achieve a foldable multi-material panel. This panel is 3D-printed flat and made three-dimensional through an integrated patterning system.
Folding was enhanced as a geometric tool through a customised process involving structural analysis prior to folding. Areas that require the most structure are densest in folds, while areas that are intrinsically structural are sparser. The folds are secured through a cable system and a clip-lock mechanism that eases assembly, disassembly, and maintenance. Moreover, an embedded micro-pattern within the system achieves passive control over the light temperature of spaces.
Euston Station’s new canopy is the large-scale architectural scenario for Metaplas. A decentralised fabrication approach is established by identifying and mapping scattered recycling and 3D printing facilities within a radius from the site. The panels are fabricated in these facilities, thereby boosting the local economy and breaking the economic displacement and polarisation caused by traditional centralised productions.
01
Multi-Polymer Foldable Panel
Decentralised Production Model
Decentralised Production Model
A comprehensive material system is achieved through additive manufacturing, aiming to produce ecological, equitable, and economic benefits.
Material Foldability Tests
Large-Scale Foldable Panel
Folding Control Through Cable and Contour Relief
A view of the cable and contour relief network embedded in the panel as a folding control system.
Material Gradient
An illustration of the material gradient distribution and mixing ration of rigid-translucent PLA and flexible-opaque TPU.
02
Digital and Spatial Approach
Folded Structure
An illustration of the digital application of the folding logic (left) and a catalogue of the folding applications (right). The physical properties of the folded prototypes are investigated according to structural analysis colours that correlate the pattern topology with structural parameters.
Mesh Variability
The mesh is manipulated to improve the structural response and is rebuilt into multi-directional quads following the shape topology.
Force Management
Gravity and elasticity are considered using tension by positioning the folding and cables strategically between the quad faces and structural colour values.
Ground Connection
An illustration of the connection between the mesh and the ground. Two separate 3D-printed pieces sandwich the mesh and secure it through pressure.
Assembly Details and Production Facilities
An illustration of component parts and the snap-lock assembly system. Parts are composed of recycled plastics and are fabricated in, and distributed to, local facilities based on their sizes.
03
Pattern, Colour, and Lighting
Embedding Channels
A detailed top view of the colour, pattern, and lighting application.
Digital Mesh Prototype
An isometric drawing showing the material application on a digital prototype.
Exploded Thermochromic Stack
An illustration of the layers involved in the passive strategy to control interior Kelvin temperatures.
Exploded Axonometric Drawing
The assembly’s layers include: Layer 1: polyactic acid (PLA) and thermoplastic polyurethane (TPU) (bottom layer); Layer 2: micropattern 01; Layer 3: micropattern 02; Layer 4: semiotic lighting; Layer 5: PLA & TPU (top layer); Layer 6: relief and cable network.
Interior Perspective
A view of the interior potential and spatial quality obtained through the use of pattern, colour, and lighting strategies.
04
Architectural Scenario: Euston Design
Computational Approach to Circulation-Based Design
Computational Approach to Circulation-Based Design
Multiple objectives are tested using computational methods to optimise the circulation-based design.
Euston Station Application
An illustration of the customised folding technique, ground connection, and cable and relief network applied to Euston Station.
Material Textures
Material Textures
Close-up details of the material system showing the intricate textures obtained through the multi-material layering and folding strategies.
Euston Station Concourse Proposal
Euston Station Concourse Proposal
A view of Euston Station’s concourse with the proposed multi-material canopy system.
Euston Station Canopy
An exterior view of the proposed canopy illuminated at night.
The Bartlett
B-Pro & Autumn Shows 2020
27 November – 11 December 2020
B-Pro & Autumn Shows 2020
Explore