Flexi Moulds, aims at developing a universal building constructions system which is based on multi materials wherein the primary material acts as a mould or scaffold while the secondary enables  in constructing the desired structure.

Our research deals with the most abundantly available natural granular material i.e SAND, which when subjected to load is best in taking heavy compression load. Apart from having the advantage of being reused, the material flow when choreographed and programmed as desired, produces complex harmonious forms and patterns. By following these patterns, we could create structures both organic and symmetric, multi layered as well as multi module structures.

A detail study of behaviour of single sand pile and behavioural change of the same pile due to interaction with multiple piles, has been our focus to generate algorithm or complex network by simulating the granules both at micro and macro level. The algorithms are generated by treating the surface of pile as contours and are used to define the trajectory of mortar flow. Also, the perimeter of piles are used to defines the curvatures while the interactive points are used to generate the main structural support system. Thus the resultant structure is designed to take compression load at all scales.

Fleximoulds is also working towards developing a insitu construction system, wherein the support material could be easily moulded and later on removed easily once the main structure is set without any technical complications. The system also aims at developing a feedback system on the real time conditions of deposition of primary material, so that any changes  in the resultant structure could be incorporated before execution. The same is also subjected to optimization in terms of material usage and structural stability.

“Con-crear” project aims to advance and contribute in the ongoing research of additive manufacturing applying as material concrete and finally revealing new potentialities. This thesis focuses on the most man used construction material deployed for a variety of projects from housing to infrastructure. It should be underlined that its price, availability and high performance are aligned to its popularity. The innate material’s behavior is studied and informed in order to liberate architecture from pre-conceived forms and sterile formal explorations while the construction process is completely visible to the outcome. The “Con-Crear”  project develops a vertical growth system in which a unit which varies within itself is being populated. The physical properties of a tubular extrusion of cement and water mix leads to a geometrical function of incremental growth informing constantly a design catalogue. In the same time, the limit of hydration and subsequently merging (of neighboring surfaces) time defines restrictions from which new opportunities of design emerge.

So, liberating the structure of the known constraints like molds and scaffolds but embedding others which derive from the material’s properties and the rules of nature (on top of all, the gravity), how much further can we go?

Stone Spray

Anna Kulik, Inder Shergill, Petr Novikov

StoneSpray is a research project which pushes the boundaries of digital manufacturing and explores the possibilities of an on-site fabrication machines. StoneSpray uses a robot that works with soil as a main building material and mixes it with a liquid solidifier and uses a jet spray system to spray the mix on the surfaces to create structures. By understanding the material nature of the mixture unique forms emerge. With the property of building structures on already existing forms and the freedom of growing structures horizontally there are a lot of opportunities for research. The growth of the structures is dependent on the material placement and experiments have been carried out with and without structural support.

More information please find on our web-site Stone Spray