The Documentation

The Documentation

- Bruder Klaus Field Chapel

Architect: Peter Zumthor

Location: Mechernich, Germany

Project Year: 2007

Materials: 

Acrylic 5mm, Plaster of Paris, Timber Rod 2mm/3mm/5mm, Plywood 2mm

Scale:

1:50

Digital Model:

Laser cutting in AutoCAD: 2mm Plywood BASE

Laser cutting in AutoCAD: 5mm Clear Acylic MOLD

Estimated vs Actual:

Time commitment - 24 days + 10 hr

Laser cut file preparation - 1 hr
Laser cutting - 1 hr
Assembling framework and base- 8 hrs
Concrete casting for 24 layers - 24 days

Actual time spent - 5 days + 19hr + 30mins

Laser cut file preparation - 1 hr

Laser cutting - 30 mins 

Assembling framework and base- 6*3 hrs 

Concrete casting for 24 layers -  5 days

Budget - $82

Silver-textured paper - $2

Plywood 5 mm - $20

Plywood 2 mm - $10

Wood sticks - $5

Laser cutting - $15

Plaster of Paris - $20

Actual cost- $106

Plywood 2mm 450*900- $14.3

Acrylic 5mm 400*300 - $19.2

Timber Rod 2mm/3mm/5mm - $18.5

Laser cutting - $15

Plaster of Paris - $39

Processes Video 

(including images and videos as the work progressing): 

https://youtu.be/gvtzmHf5_xw

Reflection:

During this model making process, the most significant tip is to follow the ratio of plaster and water as instructed as different kinds of plaster bought from different stores are not exactly the same, so it would be better to ask the staff or tutors for help. It might takes more time to let it dry if you do not precisely measure the weight of plaster and volume of water. Additionally, when modeling the frame, it will save time if you ultilise the facilities in the wood workshop for cutting and sanding the rods. For example, it takes as approximately twice the time to do it at home as in the workshop. Another thing I have learned is that making mold out of other materials like XPS foam or using mold release agent would avoid plaster from sticking to mold. In the future design studio, the concrete casting process might be involved to present the concrete material in my design. I have also taken advantage of this course to learn casting with other materials other than only cement which would be applied to my future career.

- Swiss Sound Box 

Architect: Peter Zumthor
Location: Kronsberg, Hanover
Project Year: 1996-2000

Materials: 

Acrylic 5mm, Basswood Plywood 2mm, Aluminum Wire, Right-angled Pine Strip, grey, boxboard 2mm

Scale:

1:50

Digital Model:

Sketchup Model

Laser Cutting in AutoCAD: 2mm Plywood BEAM

Laser Cutting in AutoCAD: 5mm Clear Acylic SECTION PANEL

Laser Cutting in AutoCAD: 5mm Clear Acrylic BASE and FOOTING MOLD

Estimated vs Actual:

Time commitment - 36 hr
Laser cutting and 3D print file preparation - 3 hr
3D print - 15 hr

Assembling 1:50 model - 3 hr
Laser cutting - 1hr
Metal work - 2hr
Assembling 1:20 model - 12 hr

Actual time Spent - 24 hr
Laser cutting file preperation - 2 hr 
Casting - 30 mins
Laser cutting - 1 hr
Metal Work (rods and string) - 1hr
Assembling model -
30 mins(base and section panel) + 6*3 hr(wall) + 1 hr(others) = 19hr and 30mins 

Budget - $103
Acrylic clear 2mm -$21
Plywood 5 mm - $20
Plywood 2.5 mm - $12
Laser cutting - $30

3D printing - $45

Metal and wire - $20

Actual cost - $34.35

Acrylic clear 5mm 400*300 - $9.6

Plywood 2mm 450*900 

Balsa square 1*1mm - 7*1.75 = $12.25

Aluminum rods - $12.5

Processes Video:
(including images and videos as the work progressing)

https://youtu.be/--h44Wth8xk

Reflection:

In this structure model, I have selected parts of the building to better represent its aesthetic of construction process. When doing a sectional model, adding a vertical support would make the model steady and the scored text is aimed to show your understanding of the structure. In the process, a difficulty is how to align each blocks at a straight vertical line which takes the most time. This issue is still need to be resolved even though I tried to place the blocks of upper layer referencing the lower layer. Another difficulty I experienced is the making of string as the wire with higher elasticity is hard to be bended. In the future, I will surely make a structure model to present my design so this model gives an experience in this field. 

- Allmannajuvet Zinc Mine Museum

Architects: Peter Zumthor

Location: Sauda, Norway
Area: 150.0 m2
Project Year: 2016

Materials:

Jelutong, Balsa wood square 2mm, Basswood Plywood 2mm, Black paint spray 

Scale:

1:200 and 1:500

Digital Model:

Laser Cutting in AutoCAD: 2mm Plywood BUILDINGS

3D printing in Cura: 1:500 BUILDINGS

CNC milling in Rhino: Jelutong SITE

CNC milling in Rhino: Jelutong SITE

CNC milling 

Estimated vs Actual:

Time commitment - 35 hr

CNC milling file preparation - 3 hr
CNC milling - 2 hr
3D printing file preparation -3 hr
3D printing - 5*3 hr
Model making (Timber structure) - 12 hr 

Actual time spent - 21hr + 40mins

CNC file preparation - 6 hr

CNC consultation - 1 hr

CNC milling - 3 hr

3D printing file preparation - 10 mins

3D printing - 30 mins 

Fixing model and Sanding - 5 hr 

Model making (Timber structure) - 6 hr

Budget - $135

Balsa square - $10
Timber for milling (Bunnings) - $30
CNC milling - $50
3D printing - $45

Actual cost - $304.9

Balsa square 2*2mm - 2*1.95 = $3.9

Plywood 2mm 450*900

Juletong 300*700*13000 - $148

CNC milling - $150

3D print - $3

Processes Video:
(including images and videos as the work progressing)

https://youtu.be/IHehARzLd0U

Reflection:

In this case, one thing did go wrong during the CNC milling as the Jelutong moved and the tool milled more wood which leaves a hole on the top of the surface. So I have to fix the model by adding another part of wood into the model. In order to avoid this, you are supposed to stick the solid timber on the bed using tape or screw before the milling going on. It will save time and materials if you better organise each piece in Rhino. It is tricky that the timber cannot exceed the thickness' limitation of 55mm when doing in the design futures lab. Therefore, you should slice the model into layers and reorganise it in the same level if it goes beyond the limitation. This model is really important as I have learned a new way to making site model as I used to do site model through laser cutting. However, it costs more time and money than laser cutting but leaving a nice and solid appearance. It really depends on which kind of sense you want achieve from the model. This method would be used in the future design and work, as the excellent appearance highlight the design.