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2017 Proceedings.Indb James Coleman A. Zahner Company By Any Means Necessary: Digitally Shannon Cole Fabricating Architecture at Scale A. Zahner Company 1 ABSTRACT Architectural manufacturing is a balancing act between production facility and a custom fabrication 1 Assembly of Petersen Auto shop. Each project Zahner takes on is different from the last, and not likely to repeat. This means Museum ribbons inside the A. Zahner Company factory in Kansas that workflows are designed and deployed for each project individually. City, MO. We present Flash Manufacturing, a fabrication methodology we employ in the production of architectural elements for cutting-edge and computationally sophisticated buildings. By remixing manufacturing techniques and production spaces we are able to meet the novel challenges posed by fabricating and assembling hundreds of thousands of unique parts. We discuss methods for producing vastly different project types and highlight two building case studies: the Cornell Tech Bloomberg Center and the Petersen Automotive Museum. With this work, we demonstrate how design creativity is no longer at odds with reliable and cost-effective building practices. Zahner has produced hundreds of seminal buildings working with architects such as: Gehry Partners, Zaha Hadid, m0rphosis, Herzog & de Meuron, OMA, Steven Holl Architects, Studio Daniel Libeskind, Rafael Moneo, DS+R, Foster + Partners, Gensler, KPF, SANAA and many more. This paper disrupts conventional discourse surrounding manufacturing/construction methods by discussing the realities of mass customization—how glossy architectural products are forged through ad hoc inventive engineering and risk tolerance. 190 INTRODUCTION Zahner has fabricated architectural elements for more than 120 years and has utilized digital fabrication techniques on large-scale buildings for more than 20 years. From this work we have devel- oped a breadth of experience on the trials and tribulations of delivering unique buildings. Taking on many of the world’s most complex architectural projects requires us to develop and deploy a diverse set of tools (both hardware and software) to match the expanding requirements and ambitions of architectural projects. Advances in computational design tools directly impact our work, on both our means and methods and the projects brought to us by a new generation of computationally sophisticated designers. Zahner continues to pioneer the incorporation of manufacturing methods from disparate fields (Pro/Engineer, Digital Project, 2 Dassault 3DX) to solve engineering and fabrication challenges 2 Grace Farms by SANAA and roof fabricated by A. Zahner Company (Kolarevic 2003; Glymph 2003). Through this process of appro- priation and deployment we have become experts in not only modelers. On a jobsite today one can see HVAC contractors creating custom projects but also in generating unique project scanning interiors and creating coordinated 3D models, real-time workflows. Instead of focusing on a singular fabrication process grade control on excavators, and even LIDAR-equipped drones or machine (Vasey et al. 2015; Aejmelaeus-Lindstrom et al. providing built point clouds mid-construction. Revit turns 17 2016), this paper describes an approach for mixing and matching this year and has solidified itself as an AEC standard for building production strategies and infrastructure on a per-project basis. information management by expediting drawing creation, project documentation, and delivery (Day 2017). Realizing the widely varying, intricate, and complex visions that make up modern architecture, however, also means that we need The Broad Art Museum is evidence of what a fabricator like widely varying and, at times, complex manufacturing methods. Zahner can achieve when paired with a computationally savvy Flash Manufacturing presents a solution for constantly changing design team. Today’s tools are extending the reach of architects fabrication specifications. We incorporate agility in the form of and engineers, increasing what’s possible for small teams. A modularity and reconfigurability at each stage of the production recent presentation by Zaha Hadid Architects and Front Inc. process, from CAD to CAM, to custom machine and end effector described the production of 1,212,637 unique parts for the development, to shipping and assembly instructions. Many Morpheus Hotel by a team of four people (Levelle et al. 2016). of the perceived hurdles in fabricating geometrically intricate This ability to produce more with less, along with the increasing architecture such as tooling, CAD/CAM workflows, expense, and accessibility of inexpensive CAD software, foreshadows an schedule can be countered with Flash Manufacturing. Our goal is exciting future for the built environment. to demystify parts of our process, dispelling the myth that shape is complex and perilous, while banality is simple and safe. We Mass customization remains difficult and high risk for manu- hope to shed light on the endless possibilities available with a facturers because economies of scale are not present for low collaborative design to fabrication process. volumes, and the ability to spread setup costs over large produc- tion cycles does not exist. Custom architectural production is fast In this paper, we present the case studies of the Cornell Tech paced and budget constrained. Bloomberg Center and the Petersen Automotive Museum, high- lighting subtle but salient workflow innovations that enabled their While a lack of volume makes production challenging, it also production. We conclude with thoughts on future work. provides opportunities via less strict processing requirements and reduced production penalties. Production errors are not penal- BACKGROUND ized in the same way as mass manufacturing, precisely because Digital design and construction has become commonplace within initial investment is low and quantities are smaller. This allows for the Architecture, Engineering, and Construction (AEC) Industry. impromptu tests to happen in step with production, and optimi- Form generation has never been easier thanks in part to the zation strategies can be deployed as they are developed. ever-expanding options and accessibility of high fidelity CAD ACADIA 2017 | DISCIPLINES + DISRUPTION 191 3 3 Eli & Edythe Broad Art Museum by Zaha Hadid Architects. Photo Credit Iwan Baan. When considering Kieran Timberlake’s Law of Economy and METHODS Scale (Figure 2) and how it might be upended, we propose a Making and Managing Lots of Parts: Software Automation hybrid software and hardware strategy as a means of shrinking costs and speeding delivery (Kieran and Timberlake 2004). While each project we take on is unique, a few constants exist between projects. Most architectural projects are too large to Today our software tools allow small teams to tackle large transport as a single unit because buildings don’t fit on roads. projects efficiently, increasing scope while lowering engineering This means the first step is the sectioning of the project into costs. Custom automation tools developed in house allow shippable units. Zahner’s team of ~30 engineers and architects to manage nearly 100 projects simultaneously. These shippable units are prefabricated in our factory and will only be fully assembled at the final construction site. Because of While design and computation tools have revolutionized how this, there will be no complete fit up of the parts before arriving architects work, the transition from design to fabrication is still on site. To ensure compatibility between parts and to verify we serpentine and arduous when done at building scale (Coleman et deliver the exact geometry defined by our clients, over 90% of al. 2016). As AEC software developers look to the future, devel- the parts fabricated in our shop are on Computer Numerically oping cloud-based applications and interoperable software, their Controlled (CNC) cutting devices. To fabricate a part on a CNC trajectory speaks to the nature of our industry’s nonlinearity and machine there must be a digital definition of each part and the diversity of project inputs we see daily (Day 2017). a series of support documents. These part definitions range from fully articulated 3D models to a few lines of code. Digital fabrication is a natural ally of mass customization because it’s "killer app" is the production of one-off parts, products, and for us, buildings (Gershenfeld 2012). Our software strategies are informed by a long history of interacting with digital fabrication machines and a plethora of CAD/CAM software. Our early experience on projects like the Experience Music Project (now MoPOP) or the Massachusetts 4 Institute of Technology’s Stata Center, both designed by Gehry 4 Kieran Timberlake’s Law of Economy of Scales Partners, catalyzed our shift away from paper documentation 192 By Any Means Necessary: Digitally Fabricating Architecture at Scale Coleman, Cole 5 5 Diagram of augmented punch, detail of engine turned stainless steel. to serve a specific industry and/or is based around producing and the utilization of coordinated digital models (Kolarevic 2003; a particular kind of part. We utilize many of these specialized Glymph 2003). machines because it is not economically feasible to purchase or design a custom machine for each of our unique applications. With many parts comes lots of information. A single part may Because our parts vary widely, we are often operating at the have 5 to 10 supporting elements (models, drawings, assembly edge of our machines’ specified functionality.
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