發泡成形工法與構築研究

本研究嘗試找尋突破於當前建築的材料與構築工法，參考生物生長的生成邏輯，並利用膨脹發泡材料(本研究選用PU Foam)作為建築材料，試圖發掘發泡材料所具有的膨脹與固化兩種特性所隱藏的應用潛能。本研究藉由引導發泡材料膨脹與流動的趨勢，讓建築能以類似於生長的方式自我構築，使得物體以材料自身的力道成形，並依此發展為專屬於膨脹材料且具有動態特色的新形態構築工法。在工法的理念脈絡中，期望以盡量精簡的加工方式以及資訊內涵就能夠定義出複雜的形態特徵。例如由平面或是線性的元素能夠自動生成出的拓樸的立體造型，藉由節省資訊含量，可以使得造型更為複雜，並且更適合應用於各種施工環境。本研究藉由探索發泡材料的材料特性後規劃出一種新式發泡成形工法命名為「孔洞導流成形法」，孔洞導流成形工法以發泡劑膨脹通過板片切割孔洞的方式改變發泡劑膨脹的速度差異以及傾倒方向，使得發泡劑膨脹後互相融合成特殊的造型。研究後期以此發泡工法為基礎發展三種發泡構築工法，分別為「生長式堆疊法」、「膨脹變形法」、「懸浮拓樸列印法」。生長式堆疊法結合鑄造與堆疊兩種傳統工法，並納入發泡材料常見的填縫功能以及前階段中孔洞導流成形法發掘的成形技術，整合為結構與裝飾一體製造的發泡工法。膨脹變形法試圖以雙層平面布料填充入發泡劑創造出能夠自我變形為立體造型的製造技術。而懸浮拓樸列印法以機械手臂在保麗龍顆粒中列印突破當前層積式與線性列印的造型限制與製造速度限制。以上四種發泡工法皆以簡單的控制方式創造出複雜的立體形態，使得製造技術因發泡材料的膨脹屬性而具有更多樣化的造型與成形方式。

關鍵字

數位構築；發泡成形；模具成形；膨脹材料； PU發泡劑；生長式

並列摘要

This research attempts to explore new manufacturing techniques of the expanding foam material (PU foam). We intend to find out the latent potential of foam material by manipulating the tendency of the growth of foam material, so the resulting object is shaped by the outer constraints and inner forces of the material. We propose a new foaming process named as “Stencil Diversion Forming Method” by applying stencil during the foam growth process, with dynamic characteristics that is specific to the expanded material. We also experiment with complex morphological features with streamlined processes. For example, by controlling the tendency of the growth, the blowing agent may generate a topographical three-dimensional shape through the hole during expansion. Through the holes of the stencil the speed of expansion of the blowing agent can be varied. Along with the changing of directions of pouring or twisting, multiple factors work together to form a special shape after expanding. Although this forming method tried to control or influence the foam growth by the digitally designed stencils, the unpredictability of the forming process contributes to the unique and subtle differences between each generation of the resulting form. Base on the foaming process, we have developed three foaming fabrication method named as “Growing Stacking Method” , “Expansion Deformation Method” and “Suspension Topological Printing Method”. The Growth Stacking Method combines the two traditional fabricating methods - casting and stacking. Then we incorporates the most common function of the foam material - caulking and the Stencil Diversion Forming Method. So the method can be manufactured the structure and decoration at the same time. The Expansion Deformation Method attempts to fill the blowing agent with a double flat fabric to make it self-deforming into a three-dimensional shape. The Suspension Topological Printing Method uses robotic arm to print in a pool of foam particles to break through the limitations of current layered and linear printing, and also increase the manufacturing speed greatly.

並列關鍵字

Digital Fabrication ； Foaming ； Molding ； Expanding Material ； PU Foam ； Growing

參考文獻

ARIAS, A. & MONTGOMERY, E. 2012. [Fabric]ation [Online 5/7 2012]. Available: http://cargocollective.com/charlieable/Fabric-ation [Accessed 5/23 2016].