Technology

Rapid Prototyping
Rapid prototyping was used to physically model the complex structure, both to convey the idea to the judges of the design competition, and to better understand it ourselves.

Rapid prototyping is usually used by the manufacturing industry to mock up machine parts prior to manufacture. We saw it as an ideal way to create a model of the Water Cube. Arup used two separate types: sintered nylon powder and solidified epoxy resin. The process is also called stereo lithography. To create the rapid prototype model, Arup exported the Microstation 3D model to an STL file (stereolithography).

New Technology - Key to Creation

Three years ago, standard desk top computer power would not have been able to cope with Beijing’s Aquatics Centre and the analysis, 3D modeling and final documentation which was necessary for its creation.

CSCEC proved the Arup geometry worked mathematically with a script using the Weaire and Phelan solution. This was then exported as a wire frame model into a structural analysis package. This collaboration continued throughout the entire design phase with the architect, engineer and design partner frequently exchanging 3D information models in multiple software formats, reducing all future coordination and design issues.

During the optimization phase, 22,000 steel members under 108 different load cases were tested. Its job was to test for possible scenarios, challenging it to make the steel structure strong, but as light as possible. Each and every time a new element was introduced into the design, such as a door, the structure would change to account for it.

The process involved analysis of 25000 beam size variables and 57 million design constraints in order to be satisfied for strength alone.