Floralis: an ETFE-Clad, Multilaminar Timber Structure
Authors
Principal Investigators: Dr. Masoud Akbarzadeh, Dr. Dorit Aviv, Frank Matero
Conceptual Design: Dr. Masoud Akbarzadeh, Hua Chai, Teng Teng, Yiliang Shao
Project Management: Michael Ting
Computational Design and Robotic Fabrication: Mariana Righi
Construction Consultant: Clara Shim
Construction Drawings and Detailing: Michael Ting
Assembly and Facade Erection: Michael Ting, Clara Shim, John Hinchman, Pouria Vakhshouri, Austin Chen, Maria Jose, Leechen Zhu, Michael Hirsch
Laser Surveying John Hinchman
Fabricators: Michael Ting, Clara Shim, Kodak Han, Shea Fang, Yefan Zhi, Reggie Zhao, Yi Yang, Sophia Chen, Yidi Wang, Sepideh Bayat, Pratyaya Bhattacharya, Weitzman School of Design Fabrication Laboratory Staff
Robotic Fabrication Consultants: Ester Lo, Alireza Seyedahmadian, Tristan Fischer-Smith (EventScape Inc.)
Structural Engineering Consultants: Florian Meyer, Oswald Stocker (Knippers Helbig Engineering)
ETFE Consultant: Bjoern Beckert, Fabritecture NYC
Facade Profile Production and Detailing: Ishak Hmeyed (Facade Textiles), Michael Ting
National Park Service: Penny Wagner, Jeffery Wilson, Parker Severson, Sydney Moreno
Robotic Fabrication: Eventscape NYC
ETFE Fabrication: Fabritecture NYC
ETFE Channels Fabrication: Facade Textiles International
Project Date
2022-2025
Acknowledgements
Funding was provided by National Park Services to Dr. Masoud Akbarzadeh, Dr. Dorit Aviv, and Frank Matero. The computational research fund was provided by the National Science Foundation CAREER award given to Dr. Masoud Akbarzadeh.
Description
Floralis is a lightweight, multilaminar timber structure clad in Ethylene Tetrafluoroethylene (ETFE). It was designed as a proof of concept to protect Petrified Tree Stumps (PTS) at Colorado’s Florissant Fossil Beds National Monument from environmental conditions while allowing visibility to visitors. The project contributes to ongoing research in reciprocal diagram form-finding methods, design optimization, robotic fabrication and CNC strategies, and the use of laser surveying to assist manual assembly processes.
The prototype was in anticipation of a larger pavilion that may protect Petrified Tree Stumps (PTS) at the National Monument. PTS are exposed to environmental erosion, most notably during daily freeze-thaw cycles. The pavilion prevents further erosion by forming an enclosure around the PTS, shielding the PTS from environmental conditions while beneficially not restricting the stumps’ visibility to visitors. The funnel shell geometry was materialized as an open polyhedral lattice made of sheet timber, while an ethylene tetrafluoroethylene (ETFE) foil encloses the structure.
To achieve consistency and accuracy, the sheet timber was milled using multi-axis Computer Numerical Control (CNC). Due to the pavilion’s geometric intricacies, requiring specific dimensions and miter angles for each piece, an Application Programming Interface (API) was developed to automate the transfer of milling data from the PGS model to CNC robot. In the enclosure, the aluminum channels supporting the ETFE foils were similarly mitered, and an articulated secondary structural connection was developed to affix the channels to the pavilion efficiently and accurately.
On-site construction was assisted with digital twin models created from photogrammetry and laser surveying, allowing for in-situ changes.
The pavilion was completed through three trips to the site on Florissant, Colorado, and has been outfitted with sensors to allow future evaluation of its thermal performance.
