Interlaced
Reconfigurable Thermoformed Molds for Arched System
Mackenzie Bruce + Gabrielle Clune + Colleen Ludwig
Instructors: Catie Newell + Mark Meier
This project builds on early material tests from FORM{less} to create an arch from variable blocks of plaster. The formwork for these molds is created through vacuum forming over a box with an arrangement of strings. The string pattern restricts the plastic during the vacuum forming process, creating great variation in the resulting thermoformed molds. By casting the blocks at an angle and at a specific level, the same mold can create a variety of openings for views, lighting and air flow. The openings also allow the structure of the arch to be lighter and more open at the top, aiding the stability of the arch. The same set of 5 block patterns are repeated across the arch, changing in depth and draft angle for the edge of the brick. The system created is not only adaptable in the way the molds are formed over string arrangements, but also adaptable once the molds are created.
The pattern of the vault is the result of five different string arrangements. The aggregate pattern is scripted and manipulated with locked points aligning the top and bottom. Keystone blocks have a unique pattern and aligns to the mirrored pattern creating a seamless transition.
A significant advantage of using PETG as formwork is that there is no surface preparation of the formwork for casting and no post-finishing of the concrete part as the concrete has a mirror finish cast against the PETG. Although the thermoformed plastic performs consistently when replicating a surface or pattern, the process still requires this additional material. A single pattern, when vacuum formed, can only produce a fixed geometry with limited deformation. This modified technique of vacuum forming where the PETG is pushed against a set of restrictions to create a variety of surface topologies that are not direct replications of the pattern below.
The pattern of the vault is the result of five different string arrangements. The aggregate pattern is scripted and manipulated with locked points aligning the top and bottom. Keystone blocks have a unique pattern and aligns to the mirrored pattern creating a seamless transition.
A significant advantage of using PETG as formwork is that there is no surface preparation of the formwork for casting and no post-finishing of the concrete part as the concrete has a mirror finish cast against the PETG. Although the thermoformed plastic performs consistently when replicating a surface or pattern, the process still requires this additional material. A single pattern, when vacuum formed, can only produce a fixed geometry with limited deformation. This modified technique of vacuum forming where the PETG is pushed against a set of restrictions to create a variety of surface topologies that are not direct replications of the pattern below.
