OPN x CCL
An exploration of advanced building technology
set in the rural landscape.
An industry/academic collaboration between OPN Architects and Iowa State University College of Design Computation and Construction Lab merges knowledge and resources to advance innovation in 3D printing and augmented reality technologies, materials, and methods.
"What fuels us is the discovery inherent in journey."
OPN + ISU: An unprecedented partnership
The tangible results of the OPN + ISU partnership are 3D-printed concrete curvilinear forms expanding program space at a rural public library that replaces a structure destroyed by a tornado. The installation demystifies emerging technologies and exemplifies how 3D printed concrete might be integrated into strategies for disaster resilÂience in small towns.
What inspires us most, though, is how this research could drive future innovations in our industry.
Though OPN nor ISU is new to digital design and fabrication, each brought specialized resources and expeÂrience.
After years of investing in cutting-edge technologies and implementing those into our daily workflows and traditional projects, OPN’s innovation team wanted to level up our exploration outside the confines of a client-based project.
The Computation + Construction Lab (CCL) at Iowa State’s College of Design has more than $1 million in equipment used by students and faculty for hands-on research.
Together, we created a first-of-its-kind partnership to explore real-world applications for emerging building technologies.
"We wanted to get our hands dirty and learn."
Teamwork Makes the Dreamwork
Collaborations between universities and practicing professionals
can be a vehicle to enhance innovation through the exchange of knowledge.
Collaborations are a powerful tool for bridging the innovation gap between academia and industry.
Institutions need partnerÂs to bring their ideas into production. Resource constraints often limit architecture firm’s ability to fully explore and impleÂment new technologies. Additionally, architecture firms must navigate the "build vs. buy" paradigm, deciding whether to develop custom solutions in-house or purchase from vendors.
Led by Shelby Doyle, ISU’s Stan G. Thurston Professor in Design Build, Architecture, the College of Design’s CCL offered space and equipment for OPN’s innovation team to immerse themselves in research outside the bounds of a client-focused project. Doyle and team also offered OPN exposure to research processes and expertise.
In addition to access to real-world projects that could (and would) serve as an opportunity to make the research public, OPN offered ISU funding to cover materials, transportation, machine time, and ISU faculty time/benefits for the duration of the collaboration.
"This started as a capital C collaboration"
Press Print
There are many challenges to innovation, including labor, cost, liability, and financial risk, that are often unstated and unexamined.
The team didn’t set out with a plan to print 3D concrete seating for a library. In fact, the grant that partially funded the research came from Iowa Workforce Development to explore how 3D printing might be a solution for affordable housing in the state.
The concrete follies that ultimately were installed at the library were the final result of a year-long exploration of 3D concrete printing processes, tools, and materials.
One of the first lessons the OPN team learned was how labor intensive the printing process was. Once that first bag of concrete is mixed, there’s no stopping.
The process took a minimum of four people: one person to manage the bagged material and batch mixer, one person to control the material in the pump and pump speed, one person to adjust the hose and material at the nozzle, and one person to manage software while filling in as needed to help the three others. Each print took a minimum of four hours is required to set up the equipment, print one ton of material, and power wash all the equipment.
"You can’t just press pause and restart.
Your brain needs to be on the whole time."
Augmenting Reality
AR can bridge gaps by depicting hard-to-visualize concepts to ensure a mutual understanding and improve outcomes.
Through exploration, the team discovered how the augmented can enhance the 3D printing process.
One of the challenges of 3D printing concrete is the integraÂtion of reinforcement to add lateral stability and account for forces in tension. The researchers used AR to precisely bend rebar to be used as internal reinforcement to the correct shape. OPN augmented an inexpenÂsive workbench-mounted rebar bender using Fologram for Rhino, a Microsoft Hololens 2 Mixed Reality Headset, and QR Markers to align the digital bending device with the physÂical one in AR space.
augmented reality rebar bending diagram
augmented reality rebar bending diagram
AR visualization was also used during the calibration process prior to printing to confirm the object bounds and correct alignment as well as during printing to ensure precise rebar placement. Placement on site leveraged AR by visualizing each base point on the jig and points on the face of the library building.
Using Hololens augmented reality, Hugh sets the rebar in place using the prede
From the Lab to the Library
Illustrating how 3D printed concrete can be integrated into strategies for disaster resilience in small towns
Though not part of the original concept, Rudd Public Library proved to be the ideal home for the 3D-printed objects...
On December 15, 2021, a devastating EF-1 tornado hit the small north central Iowa town of Rudd (population 348) causing widespread damage. The library was decimated physically and its collection flung far and wide. In the aftermath of this tragedy, the library board was determined to push forward, rebuilding stronger and better, if not bigger. The library was rebuilt on a new site next to the community’s recreation center.
The design of the new library takes cues from the surrounding residential neighborhood. Using simple massing and materials, the use of daylighting and open spaces expand the sense of space in the 2,300-square-foot building. Highly functional, multi-purpose spaces and flexible furnishings further serve to make the most of a small footprint
Program space is expanded to the outside with the 3D-printed concrete forms that provide the community additional areas to gather. Designed with input from the library, the curvilinear forms at varied heights facilitate movement and changes in position during use to promote physical health, enhanced concenÂtration, and engaged learning. They also engage the public visually as an artistic installation. After dark, a glowing profile miniÂmizes tripping hazards and activates the site for passersby and evening events.
"That’s the beauty of this whole project, this whole collaboration, is that it was unexpected."
GALLERY
Thank you
ISU College of Design
ISU Department of Architecture
Stan G. Thurston Professorship
Iowa Economic Development Authority
(Evans and Robison)
American Restoration and Recovery Act
(Evans, Doyle, Senske, Wu)
The University of Iowa Center for Global & Regional Environmental Research (Doyle and Wu)
Special Thanks
Rudd Public Library Design Team
Toby Olsen, AIA, Assoc. Principal, Library Practice Leader
Justin Bishop, AIA, Former Principal-in-Charge
Nick Woods, AIA, Project Architect
Bethanie Zeller, AIA, Architect I
Collaboration
Rudd Public Library Board
Rudd Community Members
Design Team
Shelby Elizabeth Doyle, AIA
Associate Professor of Architecture
Stan G. Thurston Professor of Design-Build
Iowa State University
Nick Senske
Associate Professor of Architecture
Iowa State University
Justin Bishop, AIA
Former Principal-in-Charge
OPN Architects
Jacob Gasper
Former Architectural Designer I
OPN Architects
Jamie Craine
Architectural Designer II
OPN Architects
Hugh Soward
Innovation Manager
OPN Architects
Material Workshop
Noah Callantine, Process Engineer
SIKA Corporation
Welded Elements
Wes Reynolds, AIA, Principal
Aiden Reynolds
Print Storage
Jimi Peters, AIA, Former Project Architect
Moving + Transportation
Dakota Dehnke, Architectural Designer I
Chad Moklestad, AIA , Architect I
Braden Cooper, Architectural Designer I
Tom Goetz , Architectural Designer II
Installation Support
Merlin Bishop
Documentation
Alex Michl, Multimedia Strategist
Built with Shorthand