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Morphogenesis of Curved Structural Envelopes Under Fabrication Constraints

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École doctorale Science, Ingénierie et Environnement Manuscrit préparé pour l’obtention du grade de docteur de l’Université Paris-Est Spécialité: Structures et Matériaux Morphogenesis of curved structural envelopes under fabrication constraints Xavier Tellier Soutenue le 26 mai 2020 Devant le jury composé de : Rapporteurs Helmut Pottmann TU Viennes / KAUST Christopher Williams Bath / Chalmers Universities Présidente du jury Florence Bertails-Descoubes INRIA Directeurs de thèse Olivier Baverel École des Ponts ParisTech Laurent Hauswirth UGE, LAMA laboratory Co-encadrant Cyril Douthe UGE, Navier laboratory 2 Abstract Curved structural envelopes combine mechanical efficiency, architectural potential and a wide design space to fulfill functional and environment goals. The main barrier to their use is that curvature complicates manufacturing, assembly and design, such that cost and construction time are usually significantly higher than for parallelepipedic structures. Significant progress has been made recently in the field of architectural geometry to tackle this issue, but many challenges remain. In particular, the following problem is recurrent in a designer’s perspective: Given a constructive system, what are the possible curved shapes, and how to create them in an intuitive fashion? This thesis presents a panorama of morphogenesis (namely, shape creation) methods for architectural envelopes. It then introduces four new methods to generate the geometry of curved surfaces for which the manufacturing can be simplified in multiple ways. Most common structural typologies are considered: gridshells, plated shells, membranes and funicular vaults. A particular attention is devoted to how the shape is controlled, such that the methods can be used intuitively by architects and engineers. Two of the proposed methods also allow to design novel structural systems, while the two others combine fabrication properties with inherent mechanical efficiency. The feasibility of these new structural morphologies is demonstrated by the construction of two research pavilions. A video presentation giving an overview of this doctoral work can be found online at the following URL address: https://doi.org/10.5281/zenodo.3956351 Résumé Les structures à double courbure allient performance mécanique et expressivité architecturale. Elles offrent également de vastes possibilités formelles permettant dans un projet d’atteindre à la fois des critères fonctionnels et environnementaux. Le principal obstacle à leur utilisation est la complexité qu’elles engendrent, tant du point de vue de la fabrication et de la mise en place que de la conception. D’importants progrès ont été accomplis récemment sur cet aspect par le récent domaine de la géométrie architecturale. Cependant, il reste de nombreux défis. En particulier, du point de vue d’un concepteur, le problème suivant revient régulièrement : quelles formes sont réalisables avec un système constructif donné ? Comment atteindre ces formes de façon intuitive ? Cette thèse commence par présenter un panorama des méthodes de morphogenèse, c’est-à-dire de création de forme, sous contrainte de fabrication. Puis, quatre nouvelles méthodes de génération de forme sont introduites. Elles permettent chacune d’obtenir des propriétés constructives simplifiant les procédés de fabrication. Les principales typologies de structures courbes sont considérées : gridshells, membranes tendues, voutes maçonnées, et coques discrètes. Une attention particulière est accordée à la façon dont les formes sont contrôlées, afin de garantir une génération intuitive. Parmi ces méthodes, deux permettent de concevoir de nouveaux systèmes structurels, et deux autres permettent de combiner propriétés mécaniques et efficacité mécanique. Leur potentiel est démontré par la construction de deux pavillons. Une présentation résumant ces travaux a été enregistrée en vidéo, et est accessible au lien suivant : https://doi.org/10.5281/zenodo.3956351 3 Acknowledgement I would like to start this manuscript by expressing my gratitude to all the people who made this PhD possible, who helped me at some point of the journey, or who just contributed in making this experience so enjoyable and enriching. I would like to first thank the members of the jury for taking the time to assess my work, provide their valuable feedbacks, and initiate fascinating discussions. I would then like to thank my supervisors and advisors: Laurent Hauswirth for his enthusiasm and patience in bringing me into his world of mathematics, Olivier Baverel for his guidance and enthusiasm, which initiated fruitful and exciting work, and Cyril Douthe for his nourished help on all the kinds of difficulties I encountered. I much appreciated working with the three of you. I would also like to thank the researchers who helped me overcoming scientific obstacles. In particular, Laurent Monasse for his precious help on numerical methods, Sebastien Brisard for his valuable feedbacks on shell mechanics, Johannes Wallner and Pierre Alliez for their help on discrete differential geometry models and Mathieu Lerouge for his great work on coding algorithms to construct Caravel meshes. I am also grateful to the anonymous reviewers of the research articles, some comments were highly instructive and improved the quality of the present manuscript. I also warmly thank all the people involved in the IASS and Coriolis pavilions (figures 4.2 and 4.1), in particular Alexandre, Sonia, Thibault and Guillaume for their bright design work. En Français maintenant, je remercie tous ceux qui m’ont donné des opportunité d’enseignement, à l’Ecole des Ponts et aux ENSA de Paris Malaquais et Belleville, tant cela a été une expérience enrichissante pendant ces trois ans. Un grand merci à Raphaël Fabbri pour m’avoir accueilli dans son équipe d’enseignement de géométrie et partagé son expertise sur le sujet. J’aimerais remercier toute l’équipe du laboratoire Navier de rendre cet endroit à la fois chaleureux et stimulant. Je remercie tout d’abord Marie-Françoise pour nous simplifier autant la vie, et l’équipe technique, en particulier Adrien et Christophe du fablab, et Hocine et Gilles pour leur précieuse aide. Je remercie aussi la joyeuse équipe des doctorants MSA, Philippe, Katya (auteur de la remarquable mise en contexte de la figure 5.1), Charlotte, Vianney, Leo, Tristan, tous les Julien, tous les Nicolas, tous les Paul, tous les Romains, tous les Pierre, Robin, Marie, Lionel, Laura, Deborah, Leila, Koliann, Le Hung, Sébastien et tous les autres (certains sont d’ailleurs visibles sur la figure 3.8). Je remercie Nicolas pour tous ses retours sur mon travail, et aussi pour nos discussions géométriques palpitantes. Je remercie aussi tous mes amis. Merci de m’avoir écouté patiemment parler de géométrie pendant ces années, et de m’avoir aidé à me changer joyeusement les idées. J’ai une pensée particulière pour Alberto, Hellwig, Stéphane, Charlotte, Alexia, Marie, Bianca, Vincent, William, Matthieu, Cyril, Zaza, Floriane, Gaëlle, Cécile et Meggie, vous avez été un soutien essentiel ! Je remercie bien sûr mes parents, ma famille pour leur soutien dans cette grande aventure. Compte-tenu des évènements de 2020, la soutenance de thèse a dû être reportée et finalement soutenue à distance, sans autre membre du jury présent et sans public. L’expérience aurait été bien triste si je n’avais pas été si bien entouré. Tout d’abord de Luc-Emmanuel, que je remercie chaleureusement pour avoir mis en place un studio professionnel dans mon salon pour la retransmission, et aussi pour m’avoir aidé à décompresser, par exemple en utilisant le fond vert installé pour l’occasion pour présenter la météo avec un professionnalisme déconcertant. Et entouré, enfin, de Carolina, qui a comme à son habitude rempli cette journée de joie. 5 Outline Abstract ............................................................................................................................................................. 3 Résumé .............................................................................................................................................................. 3 Acknowledgement ............................................................................................................................................ 5 Outline .......................................................................................................................................................... 6 Chapter 1 Problem statement....................................................................................................................... 9 1.1 Double curvature structures ............................................................................................................ 9 1.2 Complexity ..................................................................................................................................... 10 1.3 Recent advances .............................................................................................................................. 11 1.4 Challenges ...................................................................................................................................... 13 1.5 This manuscript ............................................................................................................................. 15 References ................................................................................................................................................... 16 Chapter 2 A panorama of generation
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