Extended metal deployé FEA analisys

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I did this project almost two years ago. Is not directly related with the computational design practice but involves algorithmic design.

Expanded metal deployé is one of the most famous cladding systems that we can find in architecture. I was contacted by IMAR company to resolve a geometry problem. They had a plug-in for Rhino to generate expanded metal sheets. The problem with the geometry generated was that produce gaps between surfaces. This is because the tool generate separately and individual pieces to form the whole sheet. In other words the plug-in generates fancy sheets but not able to create a single valid solid to export to Solid works and make deformation calculus based in FEA.

So we started working in this way: I ask them to generate as many as possible sheets with their plug-in, to have a whole family of deployé sheets. For my part I studied all these families to know exactly where are these gaps and how can be repaired. Write the code took me two weeks, and I had to implement different recursive algorithms like the quicksort and divide and conquer. The bigger problem was not repair the geometry, was optimize the code to make an elegant and economic (speed) tool. Optimize the code the code took me almost 3 more weeks. The tool calls Kompo and means fix in euskera.

Here is the geometry generated. As you can see each piece in the extended sheet is and individual element. Not possible to convert in a single mesh.

before kompo

Kompo works reading and destroying the geometry in pieces. Then use this information to generate the single shape.
after kompo

Example of the geometry tested in Solid Works
sw1
sw2

1 Comment

  • Josh Sep 29, 2014, 16:29

    Hey man,

    Epic work!

    Im just wondering if i could snag that shown expanded metal mesh model?

    its for visualisation work for uni project. Ive been modelling some in Max but cant seem to get that same shape.

    Thanks!

    Josh

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