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Self-Formed Substrate - Programmed Structural Depth for Geometric Locking of Double Curved Panels
This research seeks to lock the shape of a self-forming material system into a doubly curved, semi-space frame that leverages the anisotropic behavior of CFRPs to reduce the need for wasteful formworks. Self-forming is the programmed deformation of a flat material system into a predetermined three-dimensional geometry. Forming is typically driven by the interactions between opposing material properties of a hybrid material system. Although previous research has proven the efficacy of self-shaping materials by achieving various target geometry, the structural locking mechanisms and connection strategies for scalability of their material systems were mostly left out of scope. In this thesis, a hybrid material system of semi-cured carbon fiber and highly stretchable membrane self-forms into a programmed structural height is used as a flexible core material for a CFRP space frame panel with localized, double curvature. The fabrication is done through the tailoring of the fibers with the use of a tailored fiber placement (TFP) machine on both sides of the membrane. A digital flattening and subsequent self-forming simulation serve as the basis for controlling both the self-forming process and bending into the programmed, double-curved target geometry. The forming of the localized curvature is achieved by leveraging the flexibility of the semi-cured, self-formed substrate through the application of a bending active frame that is integrated as the connection of multiple components. Finally, a custom method for applying a top and bottom layer of additional fibers that is materially optimized for structural loading is added.
ITECH M.Sc. Thesis Project 2022: Self-Formed Substrate - Programmed Structural Depth for Geometric Locking of Double Curved Panels
Hyowook Kim, Kevin Saslawsky, Chien Chun Kuo
Thesis Advisers: Axel Körner, David Stieler
Thesis Supervisor: Prof. Achim Menges
Second Supervisor: Prof. Jan Knippers