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 Fiberglass Wrapped Structural Nodes  *°

DCS ° TipTap & Rocker

DATE2018

LOCATIONHouston, TX

TYPEMaterial & Fabrication Research

FUNDINGLawndale Center for the Arts & Rice School of Architecture

PRIMARY INVESTIGATORDavid Costanza

RESEARCH TEAMPhilip Niekamp
Ekin Erar
Samantha Schuermann

OVERVIEWThis research explores a hybrid approach to structural design and fabrication, combining standardized industrial components with custom-fabricated joints. Developed through a series of full-scale prototypes, the research culminated in TipTap, an interactive public installation that investigates material performance, digital design, and spatial play. The work demonstrates the potential of digital manufacturing and composite materials to produce precise, durable, and structural joints.

KEYWORDS3D Printing, Fiberglass, High-Performance Textile Composites, Structural Nodes

DESCRIPTIONThis research aims to reconcile the efficiencies of off-the-shelf components with the design freedom of custom fabrication. By using industrially produced 2” structural fiberglass pultrusions in combination with custom 3D-printed nodes, the system allows for precise geometric control while maintaining scalability and ease of assembly.

DESIGN STRATEGYEach node was generated using a parametric model and fabricated by 3D-printing a mold, which was then wrapped in fiberglass tape. The print itself was non-structural—serving only to define the geometry. Varying tape widths were applied based on local curvature. Nodes were vacuum-bagged to consolidate the lamination, resulting in strong, moment-resisting joints. The fiberglass members were inserted into the cured nodes and adhered using epoxy.
        This lightweight structural system supports two woven surfaces, enabling the object to be occupied both spatially and physically. 1/2” marine-grade polypropylene rope was used to create the woven surface, forming a soft, dynamic interface that invites playful engagement.

FABRICATION PROCESSThe frame assembly began with three planar sections—at both ends and at the center. Due to the non-directional nature of the round members, clamps were used to maintain planarity during assembly. Once these planes were established, the ruled surfaces were completed without the need for jigs or molds.
        The weaving process was iteratively developed through full-scale tests. In the final prototype, two rope colors were used to distinguish the weave’s two directional grains: orange for the longitudinal warp and yellow for the transverse weft. Rope also wrapped the vertical members, creating visual cohesion across the structure.

PROTOTYPE TESTING: THE ROCKERAn initial prototype—referred to as the Rocker—was installed on the Rice University campus for seven months of public testing. The prototype allowed us to evaluate material durability and user interaction under extreme outdoor conditions in Houston. Observations from this testing directly informed the final design and construction of TipTap.

FINAL INSTALLATION: TIPTAPSixteen months after receiving the RDA project grant, the final installation of TipTap began. Building on previous prototypes, the design introduced a key refinement: a split seam along the hinge axis. This seam enabled the structure to be divided into two parts, each transportable by truck.
        Before fabrication, a full-scale prototype of the seam detail was produced to verify the joint’s ability to transfer structural loads across the two halves. The final piece consists of 36 custom nodes, each 3D-printed, wrapped in fiberglass, vacuum-bagged, and finished with bondo putty and marine-grade paint.

CONCLUSIONThis research exemplifies how digital tools, specifically 3D Printing coupled with composite materials, can transform conventional structural logic into a modular, expressive, and responsive system. Through hybrid fabrication methods, the project demonstrates how lightweight, non-standard assemblies can be produced efficiently while fostering public engagement and playful interaction.

ed into two parts, each transportable by truck.
       

DCS