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Nicholas Bruscia

Structural Papercuts University at Buffalo, State


University of New York

Scaling Disclinations in Self-Reactive Surfaces

ABSTR ACT
This paper reviews and explores the topological properties of surface disclinations applied 1 [+x°] wedge disclination
prototype.
to elastic sheets and suggests how these properties may be reproduced at an architectural
scale. A variety of surface disclinations and their translation from digital and physical form-
finding processes to thin plywood prototypes are discussed. Initial phases of this research
have been focused on the bending behavior of various sheet disclination types and have
studied a variety of computational form-finding techniques that demonstrate this behavior in
an architectural workflow. Several large-scale prototypes of architectural disclinations were
produced to test the scalability of topologically induced surface curvature, discussed within
the context of bending-active plate structures.

536
INTRODUCTION
The basic topological concept of a disclination acknowledges
the role of the “defect” in the composition of a material
structure. However, the basic principles of disclinations
can be applied to material systems at multiple scales. For
example, the process of strategically inserting geometric
disclinations in woven lattices results in out-of-plane buck-
ling, producing concentrations of either positive or negative
2a
curvature (Martin 2015) (Fig. 2a). Similarly, thin sheets
absorb the strain induced by disclinations by buckling into
repeatable, complex forms (Harris 1977). Since complex
surfaces must often be postrationalized with a geome-
try-based approach prior to construction, it is useful to
investigate approaches that are directly related to material
properties that reinforce rationality from the start, helping
to define alternative and more efficient design processes
and fabrication techniques.
2b

Surface Disclinations
Disclinations depend on rotational symmetry, usually
around the center axis of a torus or a sphere. This differs
from dislocations and dispirations, which rely on transla-
tional and screw symmetry, respectively (Harris 1978). The
work in this paper focuses specifically on compact disclina-
tions of rotational movement to force out-of-plane bucking
2c
in thin sheets. For example, wedge disclinations in flexible
sheet materials can be built to conceal the topological
condition that creates curvature through self-reaction, a
rather elegant construction technique (Fig. 2b). The strain
applied to the material during assembly is eventually distrib-
uted smoothly (Harris 1977), and it has been empirically
observed via physical models that some surfaces resulting
from wedge disclinations are bi-stable since the surface
exhibits snap-through buckling as it is forced to move
between two stable positions. When stable, the surface
remains in a state of self-reaction where strain is distrib-
uted smoothly (Kroner and Anthony 1975).

Disclinations in sheet materials can be created with a


simple procedure. By slicing through the material along a
straight line but not entirely across, one can choose how
to reconnect the surface ends in order to induce self-reac-
2d
tive curvature. By removing material prior to reconnection,
positive curvature is created. By adding material prior 2a <6 and >6 edge count polygons 2b [+60°] and [-60°] wedge disclina-
introduced to the regular lattice tions: a 60° sector is removed to
to reconnection, negative curvature is created as the
produce positive and negative form a cone or added to the disk
surface reacts by buckling into a [-x°] wedge disclination. Gaussian curvature (Ayres et al. to form a saddle-like surface
For example, a [-360°] wedge disclination performed on a 2018). (Harris 1977).

circular sheet gives rise to severe deformation resulting 2c [+90°] and [-90°] wedge disclina- 2d Top-down view: [-360°] wedge
tions illustrated as cubic lattices, disclination creates extreme
in a saddle-like surface (Fig. 2d). Formally, this results in
shown here in comparison to buckling. The inserted “wedge”
a surface drawn from two double cones, as the surface similar topologically induced itself is a full circle (Harris
can be generated by moving a straight line fixed at one end bends in woven lattices and thin 1977).
sheets (Harris 1977).
(Harris 1977).

LABOR AND PRACTICE 537


3a Josef Albers, curved-crease sculpture. 3b Naum Gabo, Spheric Theme.

3c 2-circle [-x°] disclination. 3d 3-circle [-x°] disclination. 4 Ilhan Koman, π+π+π+... sculptures.

Naum Gabo was perhaps the first to document this technique exercises of the Bauhaus and later at the Hochschule für
in built form in the 1930s, but it was later discussed as a Gestaltung Ulm (Ulm School of Design), it is useful here to
wedge disclination by crystallographer William Harris who recall the pedagogical work of Josef Albers that produced
characterized them with negative or positive angle measures, the first account of a curved crease model (Fig. 3a) consisting
which is the notation adopted in this paper (Harris 1977). of concentric circles (Demaine et al. 2011). The alternating
Similarly, Turkish sculptor Ilhan Koman cataloged the various concentric mountain and valley folds along the curved
surface variants as factors of pi (Akgün, Koman, and Akleman creases results in a saddle-like form quite similar to Naum
2006). In both instances, the degree of rotational move- Gabo’s Variation on a Spheric Theme (Fig. 3b), and Harris’s
ment and the amount of material inserted into (or removed [-x°] wedge disclination in a circular disk (Figs. 3c, 3d). In
from) a single disk is made explicit. Another way to describe comparison, the [-x°] wedge disclination can also produce
surface disclinations may be possible with the Gauss-Bonnett a wide variety of results since it is not limited to the surface
theorem that relates a surface’s geometric curvature to its area of a single circle. This is demonstrated by Ilhan Koman’s
topological Euler characteristic. While a proper investiga- developable sculptures in [π+π+π+....] form, which clearly
tion into this relationship is beyond the scope of this paper, illustrate the variety of distinct surface types that emerge
its relevance to this work is illustrated by mathematician from this process (Akgün, Koman, and Akleman 2006) (Fig. 4).
Edmund Harriss’s Curvahedra system and its application to These examples and their history of multidisciplinary explo-
large sheet metal sculptures (Harriss 2020). ration help demonstrate that working with paper leads to a
fundamental understanding of form making and efficiency
BACKGROUND AND REL ATED WORK of means. Since the material will be utilized to its maximum
This paper borrows its title from László Moholy-Nagy, who potential, complex design proposals with little waste result
in Vision in Motion described beginning design exercises from a simple material process (Demaine et al. 2011).
of manipulating flat sheet materials into three-dimensional
structures (1947). Paper cutting and bending is an effec- While the primary motivation driving the research is to
tive form-finding process since some basic understanding explore surface disclinations at an architectural scale, the
of the strength of materials, role of grain direction, and the work takes inspiration from several case studies that have
varying tension and compression forces can be inferred from either directly or indirectly influenced the results to date. An
small-scale models. For example, both grain direction and appreciation for thin sheets formed within the limitations of
slight overlapping of material can determine in which of the their material characteristics is inspired by the Plyform work
two stable states the model will tend to rest. If unintended, of Charles and Ray Eames in conjunction with the Molded
this may bias the bending behavior and affect the evaluation Plywood Division of Evans Products in 1943. The Eameses
of the model. Building on the origins of foundational design constructed a variety of large-scale molded plywood parts

538 Structural Papercuts Bruscia


materiality, perhaps surface disclinations may also be seen
as an elegant combination of the structural and geometric
qualities of bent surfaces.

This work also takes inspiration from prior research on


bending-active plate structures, a structural system that
is characterized by the use of large elastic deformations of
initially flat planar materials (Knippers et al. 2011). These
systems use bending to enhance their structural properties,
as opposed to traditional building structures that aim to limit
the amount of bending. Controlling a material’s flexibility to
produce self-stabilizing potential energy has proven to be a
versatile approach to designing lightweight shell structures
(Schleicher and La Magna 2016). Prominent examples include
Buckminster Fuller’s plydomes, the 2010 and 2015–16
Research Pavilions by the ICD/ITKE at the University of
Stuttgart, as well as the Berkeley Weave and Bend9 installa-
tions at UC Berkeley’s College of Environmental Design.

5 Charles and Ray Eames, airplane fuselage, 1943.


METHODS
In order to demonstrate the potential application of surface
for the U.S. Navy, built from enormous pieces of wood veneer disclinations in an architectural context, it is necessary to
and pressed into doubly curved aircraft sections. The scale understand their topological and geometric nature. While it is
at which they managed to mold plywood components and possible to approximate surface disclinations with manually
the pinch-forming techniques they devised to hold specific constructed conic sections, the natural surface curvature
curves may be best exemplified by their airplane stabilizer tail created by bending against restrictive material constraints
and airplane fuselage (Fig. 5). A similar source of inspiration is seen as an opportunity for nuanced formal variation
comes from the construction of early wooden monocoque and control via computational simulation. The geometric
shells built for racing airplanes in the early 1900s, specifically construction of the approximated topology prepares the
because the fuselage was constructed from multiple layers physics-based simulations that are explored alongside
over a removable framework. For example, the Deperdussin paper model bending. An iterative physical modeling process
monoplane was constructed of three 1/16 inch layers of using paper stock assists, and in specific cases provides an
tulip wood glued over a mold (Hoff 1946). The prototypes alternative to, the computational form-finding techniques
discussed in this paper were built to a similar thickness, but developed in this phase. For example, it was empirically
from two layers of 3 mm bendable poplar plywood without a observed that how the paper stock is reconnected (the sided-
mold or supporting framework. ness of the material overlap) will determine which of the two
stable states the model will tend toward. Reproducing this
Various early paper models and the finished prototype of the behavior digitally is interesting territory to explore. At this
[+x°] wedge disclination share a likeness to Skating Shelters stage, however, the simulations are intended to approximate
by Patkau Architects. The standard 4 × 8 ft dimension of either of the two stable states that are revealed by the paper
plywood sheets was a limitation to overcome, resulting in models. This seemingly inherent characteristic of bi-stability
the assembly of larger panels consisting of lapped layers. has inspired future work toward large-scale components
The layers were cut to a pattern specific to a recipe of grain designed to counteract one another as they are forced
orientation and bending bias (Patkau Architects 2017). The to connect between stable states. The opposing potential
shelters are constructed from bendable anisotropic plywood energies may find a productive equilibrium, suggesting the
designed to bend along one axis relative to the sheet propor- possibility for larger structures.
tions, which are made of a single veneer core and two thicker
outer layers with grain orientation in the same direction. The Acknowledging the role of the paper models and their
prototypes discussed adopt the double-layer approach to ability to demonstrate interesting topological behavior, a
scalability and make use of a bendable poplar plywood with materials-based form-finding approach is preferred over
grain orientation in either the short direction (barrel grain) a top-down approach to form-conversion in this phase,
or the long direction (column grain). Similar in spirit and in although the latter may become a useful technique for more

LABOR AND PRACTICE 539


a Lengthen concentric polylines. b Bending forces counteract polyline expansion. c Check unrolled mesh for spiral overlap. d Use generating lines to create ruled srf. 6

a Fold base mesh to increase srf area. b Apply bending forces, allow mesh to take shape. c Check unrolled mesh for spiral overlap. d Use generating lines to create ruled srf. 7

complex assemblies that require an array of embedded discli- of π inserted into a flat disk need not be predetermined if
nations. To date, [-x°] disclinations have been of particular the simulation accounts for self-reactive bending; the user
interest since their resultant form cannot be fully predeter- simply increases or decreases a number slider to achieve
mined through explicit 3D modeling. As mentioned previously, more or less curvature in the surface. In this example, the
the material is self-reactive in the forming process (physical numeric input is not entirely abstract; the number slider
models benefit from surface self-collision), the simulation of domain is set between 1.0 and 2.0, which is a multiplying
which has proven to be a challenge worthy of pursuit. factor of the concentric mesh edge lengths that relate
directly to real-world dimensions.
Computational Form Finding
This section describes the computational form-finding Digitally “inserting” material into the disk through differen-
techniques carried out in this research to date, in compar- tial edge expansion is comparable to predetermined paper
ison to other known approaches to similar modeling stock insertions and mathematical insertions of factors
problems. The multistep form-finding techniques described of π since the formal result is the same. This is perhaps
below utilize physics-based dynamic relaxation tech- equally intuitive, since one can first use visual judgment
niques in Kangaroo2 (Piker 2013), and are consciously to confirm the desired outcome and extract specific
developed within the tradition of form-finding strategies dimensions and the amount of surface area addition later,
of architects and engineers from the 1950s onward that postsimulation in a multipart workflow. In summary, a
incorporated materials and forces in the systematic topology approximation is modeled using line and mesh
exploration of lightweight structures (Schleicher and La elements that organize the applied forces with the goal
Magna 2016). Now a common tool in architectural design of finding an accurate, developable surface that can be
and research, Kangaroo2 has played an important role in unrolled within a very small percentage of dimensional
visualizing the resultant geometry of surface disclinations and area deviation (<0.5%, as determined by Rhinoceros
based on the application of forces and counterforces in 3D ruled NURBS surface creation and unrolling in dozens
meshes drawn specifically for this purpose. In addition, of trials) (Robert McNeel & Associates 2020). The unrolled
the real-time feedback allows for simple numeric input surface is then discretized into parts that fit onto standard
to control the outcome. For example, a single simulation plywood sheet sizes for CNC fabrication.
can very quickly produce [-x°] wedge disclinations from
very small fractions of π, up to or nearing a full π inser- Technique 1—Expanded Concentric Polylines: The [-x°] wedge
tion ([-360°]). Multiple π insertions are possible if surface disclination is created by inserting a wedge of material into
self-collisions are solved or if a different approach is taken a circular disk. When reconnected, the increased surface
to model the initial topology. However, the exact amount area is forced within the original dimensional boundary,

540 Structural Papercuts Bruscia


a Sphere and double-cone intersection. b Trim/join alternating conic sects. at tangents. c Create mesh and expand concentric mesh edges. d Use generating lines to create ruled srf. 8

a Pull together selected mesh vertices. b Weld mesh to align vertices and continue c Snap together lower mesh anchoring vertices. d Rotate folds toward vert. center axis. 9
bending across seam.

forcing out-of-plane buckling. To simulate the expansion of between the cones and spheres creates circles that can be
surface area, a simple quad mesh is produced as a control split into continuous curves that form the outer and inner
polygon. The concentric polylines are extracted and forced to surface profiles. A ruled surface is drawn between the
expand while the radial polylines are forced to maintain their profiles and subdivided into an evenly distributed, quad-de-
starting lengths. The factoral input of linear expansion can be pendent triangle mesh. One could also simply trim the cones
converted to document the increase in rotational degrees (the using the intersecting circles and the tangent lines between
starting point being 360° for a flat disk). Bending forces coun- the cones, producing congruent conic sections that can be
teract the expansion within the constant diameter, forcing combined to form the approximated surface. The mesh is
an out-of-plane reaction (Fig. 6). In this and the following relaxed and bending forces are applied, resulting in a more
examples, the mesh is tested for unroll planarity, and radial natural saddle-like form, and the concentric mesh edges are
polylines are straightened in place upon convergence and expanded or contracted to control the surface geometry. Note
used to produce a ruled NURBS surface for further discret- that this technique of inscribing cones into the cube is useful
ization into smaller parts, which are detailed for full-scale to create initial surfaces of [-720°] (4π) by adding a third
assembly. double cone between the remaining two opposite faces of the
cube followed by the previous steps. For a clear example, and
Technique 2—Relaxed Folded Mesh: A circular boundary a technique to account for formal variation by adjusting cone
surface is separated into four quadrants. Each surface is apertures and inscribing their base circles in n-gonal poly-
rotated along its two bounding radii, forming two intersecting hedra, see Verhoeff and Verhoeff’s (2014) modeling of their
surfaces within each quadrant. The line of intersection is Lobke sculptures.
used to create new surfaces resembling a series of accordion
folds. The polysurface is converted into an evenly distributed, These techniques result in near-identical surfaces. This is
quad-dependent triangle mesh with up to twice as much intentional and highlights that while the base topology and
surface area as the original circle but maintains its original simulation strategy are devised with a particular disclination
diameter. Bending forces applied to the mesh allow it to relax variant in mind, the result is a reliable approximation suitable
naturally into the expected saddle-like form (Figs. 7, 10a). for the transition to larger scales.

Technique 3—Double-Cone Intersection: To demonstrate the Additional Approaches


[-x°] wedge disclination’s conic geometry, a simple approx- In addition to the above, other digital form-finding techniques
imation is produced by intersecting a set of two opposing were used to simulate [+x°] wedge disclinations. The develop-
double cones with a large and small sphere, all of which ment of the base topology as well as the controlled motion to
share a common center point (Fig. 8). The intersection induce bending were directly related to the way in which the

LABOR AND PRACTICE 541


10a Folded mesh bending with polygonal profile.

10b 2-pentagons with 72° overlap. 10c [-288°] wedge disclination prototype.

paper models were formed. This technique is more straight- woven lattice. Technique 3 may be comparable, as the crude
forward since these particular interpretations of the [+x°] base mesh is developed with a predetermined disclination
wedge disclination do not involve the addition (or lengthening) form, which is then relaxed to approximate the bending
of material. Rather, they are designed with the removal of behavior.
material in mind, and are digitally pinched together to form
single conic shells as well as small clusters of two, three, and Finally, some paper modeling exercises have helped define
four connected conic shells (Fig. 9). This is similar in setup to the physical vs. digital modeling relationship. The [-x°] wedge
the “effective pinching” technique demonstrated by Schleicher disclination prototype above was designed with two penta-
et al. (2015), and similar in practice to the simulation tech- gons that overlap 72° (sharing one edge) at the start and end
niques demonstrated by Soriano et al. (2015). While the of the bending sequence (Figs. 10b, 10c). The full face overlap
former example is not defined as a disclination, since a rota- specifies the amount of material insertion by degree, in this
tional transformation is not required, the latter does exhibit case creating a [-288°] wedge disclination with a polygonal
the result of rotational movement in the mesh after a wedge of outer profile, and sets the appropriate amount of layer
material is removed in order to simulate positive curvature in overlap needed for consistent bending across seams. Since
an elastically bent sheet. Methods described in Soriano et al. the paper model dictates the limits of form finding by virtue
for modeling the effect of mesh singularities on elastic planar of the number of polygonal faces, a variety of digital modeling
meshes toward negative curvature may be compared to the techniques could apply so long as they satisfy the intended
techniques described above. Specifically, a separate square degree of rotational bending and material overlap.
mesh portion is inserted into a half-length cut within a larger
square mesh, forcing the mesh to curve into a saddle-like RESULTS AND DISCUSSION
form; a process that compares to technique 2. Second, their The challenges of scaling self-reactive surfaces are partially
“plate network” simulation process is similar to technique due to the dimensional limitations in sheet materials (Leinhard
1 in that the base topology begins flat until a change in the and Knippers 2013). A common approach to scaling the
topology forces the buckling, and because material overlap bending active technique has been to localize the bending
that occurs in reality is avoided in favor of a faster and more forces into smaller parts within an aggregate assembly
reliable digital simulation (Soriano et al. 2015). Another (Schleicher et al. 2015). Instead, this phase of the work opted
comparable technique is demonstrated by Ayres, Martin, to build large, flat two-layer plywood sheets. The sheet, shaped
and Zwierzycki (2018) that uses a variety of adjustments to specifically to accommodate the desired finished form, is
low-polygon meshes in order to establish an appropriate itself discretized prior to bending. To test the scalability of
valence structure required for a triaxial woven pattern prior the surface disclination workflow described previously, a
to relaxing the form into a more accurate depiction of the series of plywood prototypes onto which a partial fiberglass

542 Structural Papercuts Bruscia


11a Plywood layer blending with serrated profiles.

11b Expansion and contraction in joints. 11c Fiberglass sew-up.

layer was tailored, stitched, and cured with epoxy resin were state, making a glued connection difficult and increasing the
constructed. Each utilized a similar technique to overcome chances of delamination (Bechert et al. 2016).
the dimensional limitations of plywood sheets by interlocking
serrated profiles, allowing continuous bending across panel An additional challenge is that due to material thickness,
seams. New connection types have proven necessary as the layers slide as they bend at different rates. Tolerance is
thin materials have become more common in research on achieved by fitting M3 bolts and nylon-inserted locknuts, which
timber shell construction. Typical jointing techniques that are act to set the position of each part within their respective
optimized for thicker materials do not account for consistent layers but allow 1–2 mm of movement during the bending
bending across ultra-thin materials (Schwinn, Krieg, and process (Fig. 11b). Bending occurs prior to the tightening of
Menges 2016). In order for the assembled flat sheet to bend the bolts, which locks the layers and sets the form. In this
across seams evenly and without concentrating the stresses phase of the research, the bolts remain during and after the
to a single layer, a deeply serrated edge profile for each layer composite lay-up, an area of necessary improvement (Fig. 11c).
part was devised (Fig. 11a). The layers blend into one another, To follow, a fiberglass “jacket” was added to provide stiffness
thereby avoiding a continuous split in the two-layer sandwich. and protection from the elements. The textile was cut to match
In other words, the seam is never perpendicular to the bending the surface profiles, manually sewn onto the pre-bent plywood
direction (or parallel to the bending axis), and the two-layer assembly through CNC-machined holes along the edges. This
thickness is maintained across the vast majority of the seam. is also an area of intended improvement, and will likely be
As prototyped from 3 mm thick plywood with uniform grain substituted with the application of preimpregnated composite
direction, the two-layer serrated seam technique performs strips. The layup sequence and geodesic patterning as they
very well for bending across surfaces with dimensions larger may relate to the analysis of surface stresses and areas
than stock material constraints, although in some cases a of weakness are seen as necessary steps toward realizing
considerable reduction in bending resistance was observed. surface disclinations at an architectural scale.

There are added benefits to the double-layer construction, OUTLOOK AND CONCLUSION
for example, the ability to orient grain directions to influence The work outlined in this paper is intended to demonstrate
the local bending behavior, as demonstrated in the ICD/ITKE the potential of surface disclinations at a large scale, and
2015-16 Research Pavilion (Schwinn, Krieg, and Menges is proposed as the preliminary step toward a more robust
2016). Also, the double-layer construction allows for lapping fabrication technique and associated computational
across large dimensions that avoid the awkward accumulation workflow. A wider range of surface disclination strate-
of material and consistency of thickness throughout. A draw- gies and how they may combine to form larger aggregate
back is that the layers need to be joined while in a deformed constructs is currently being developed in parallel with new

LABOR AND PRACTICE 543


12 [+/-90°] twist disclination prototype. 13 [+180°] wedge disclination prototype.

developments in the form-finding process and simulation Moussa, Rebecca Flanagan, Stanicka Mathurin, Mehrad Naghizadeh,
approaches. A more direct connection between the composite Kajal Patel, Yogesh Ravichandar, and Timothy Zeng for their contrib-
lay-up process and simulation is seen as an important uting work as part of the fall 2019 STRG design studio. The author
step to directly connect the on- and off-screen work. This would also like to thank the peer reviewers for their extremely
includes finite element methods for analyzing potential helpful comments and suggestions.
bending stresses both during assembly and under loading
to help predetermine fiber directions along the surfaces REFERENCES
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Nicholas Bruscia is an Assistant Professor in the Department of
Robert McNeel & Associates. Rhinoceros. V.6.0. Robert McNeel & Architecture at the University at Buffalo, State University of New York,
Associates. PC. 2020. where he is also a researcher in the Sustainable Manufacturing and
Advanced Robotics Technology (SMART) Community of Excellence.
Schleicher, Simon, and Riccardo La Magna. 2016. “Bending-Active A strong interest in architectural geometry and enthusiasm for
Plates. Form-Finding and Form-Conversion.” In ACADIA 2016: calculated formal and structural elegance informs much of his work
Posthuman Frontiers: Data, Designers, and Cognitive Machines with materials and fabrication processes. He has over a decade of
[Proceedings of the 36th Annual Conference of the Association for experience in applied digital design media, and his primary role in
Computer Aided Design in Architecture (ACADIA)], Ann Arbor, MI, collaborative projects has focused on the workflow associated with the
27–29 October 2016, edited by K. Velikov, S. Ahlquist, M. del Campo, design and realization of large-scale prototypes.
and G. Thün, 260–269. CUMINCAD.

Schleicher, Simon, Andrew Rastetter, Riccardo La Magna, Andreas


Schönbrunner, Nicola Haberbosch, and Jan Knippers. 2015.

LABOR AND PRACTICE 545

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