PRODUCTION DAY 4: GLUING FLANGES

Gluing jigs were prepared to ensure a 3" (the thickness of the backer panel)
offset from the base of the extrusions.  

Pre-cut flanges with holes for securing the components to the backer panels. 

The team in an assembly line fashion. 

 

Cleaning the jig.

Scraping excess glue.

 

The component drying in the jig.

The team hard at work.

The collection of completed components. 

  

A demonstration of the fitting.  

PRODUCTION DAY 2: DRILLING FLANGES

As part of the full component, the extrusions also encompass 3 flanges on either face. These simply allow for connection into the backer panels. 

Jonathan using the drill press.

522 flanges in total.

DIGITAL MODELLING PROCESSES

Existing steel structure

Backer panels

Backer panels with milling information

Extrusions

Flanges 

19" equilaterally triangulated surface 

Etch lines for back of panels (to insert extrusions)

Cap panels

Final wall construction

CNC sheets