Manufacturing Surface Effects

Branko Kolarevic
Ball State University
Abstract
The paper examines the newfound capacity to digitally design and manufacture highly crafted
material and surface effects. It traces an emerging trajectory in contemporary architecture aimed
at the decorative effects of digitally crafted surface patterns and textures, as a potential return to
ornamentation in architecture. It surveys practices whose approach to form and pattern varies from
the ornamented minimalism of Herzog and de Meuron to the expressive exuberance of Greg Lynn.
The paper also describes the different digital modes of material production aimed at particular surface
effects, as in series of panels with repetitive, yet unique decorative relief or cutout patterns, striated
surface configurations, etc.

Introduction
The properties of a buildings surface
whether it is made of concrete, metal,
glass, or other materialsare not
merely superficial; they construct the
spatial effects by which architecture
communicates.Through its surfaces a
building declares both its autonomy and
its participation in its surroundings.

Leatherbarrow (2002)
Soon after the NURBS-based
curvaceous shapes started to appear on
computer screens in the early 1990s,

the ambition in the use of materials was

to express the seamlessness and the
smoothness of form. Bernhard Franken
(2003) described several of his projects
for BMW as an explicit attempt to hide
the connections between components,
to achieve the smooth appearance
characteristic of the cars manufactured by
his client. Future Systems aimed for similar
smoothness of appearance in several of
their projects, such as the Media Center
at the Lords Cricket Grounds in London.
To some extent, that smoothness and
seamlessness insured only one design
scale mattered: it was the overall form and
shape that were primarynothing was

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allowed to distract from the expressive

and atypical geometry of the exterior skin.
The infatuation with complex
geometry in mid-1990s soon branched
into the computational exploration of
highly crafted surface effects that led to
a reemergence of pattern and ornament
(by association), which had been banished
from architecture for a large part of
the twentieth century. This shift toward
the ornamental or decorative stemmed
partly from pragmatic requirements
which building skins have to satisfy, partly
from purely aesthetic considerations,
and partly because of the old-fashioned
need for scale and tactility in buildings.
The emergence of the new digitally-based
techniques of design and production
opened up new ways to introduce pattern,
texture and relief onto architectural
surfaces (Kolarevic 2003, 2004).
Greg Lynn, for example, developed
various strategies of creating apertures
in the curvy skins of his building through
shredding; the smooth morphology was
adapted to the pragmatic requirements of
bringing light and air into the buildings. The
resulting striated, shredded surfaces attain
a changing but smooth rhythm, a pattern of
alternating voids and solids that can both
dematerialize parts of the skin or render
the skin as a whole almost entirely opaque
depending on the viewing direction; the
shredding also adds a much needed
sense of scale. In addition, the shredding
can provide for a subtle, dynamic optical
effect resulting from the changing angle of
the viewers eyes to the surface, which was
aptly demonstrated by the shredded skin
of twisted copper strips in the Signal Box
by Herzog & de Meuron.
Among contemporary design practices,
Herzog & de Meuron stand out in their

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unapologetic exploration of pattern,

texture and relief and the resulting
material and surface effects they can
produce. The ornamented minimalisma
seemingly minimalist geometry of the
building, often wrapped with a highly
decorative skinhas become their signature.
In the Eberswalde Library, a conventional
box building with horizontal, alternating
strips of concrete and glass, images were
silk-screened onto glass and concrete
panels, literally blurring the material
distinctions between the two. The new
addition to the Walker Art Museum in
Minneapolis, similarly, features a skin made
from crumpled, aluminum mesh panels,
a blur between solid, translucent, and
transparent in the words of Jacques
Herzog. Ornamentation is not limited
to the building skin only, however; the
interior surfaces of the museum addition
are likewise decorated by swirling, lacy
patterns cut in wood or embossed in
metal panels.
The scale of decoration in the buildings
by Herzog & de Meuron can vary vastly,
from several feet to several hundred feet.
The large surfaces of the rain screen at
the De Young Museum in San Francisco
are made from over 7,000 copper panels
(12 feet by 2 feet in size), each of
which features unique halftone cutout
and embossing patterns abstracted from
images of the surrounding tree canopies
(figure 1). The circular perforations and
indentations produce abstract images
when seen from a distance, similar to how
halftone patterns of dots of varying size
fool the eye into seeing different shades
of gray in newspapers. The rain screen
cladding is obviously decorative, but it
also has a purely functional purposeto
hide an integrated ventilation system and

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Digital Making: Superficies: Integral and Applied

Figure 1. The perforation and indentation patterning of

the rain screen panels in De Young Museum by Herzog
& de Meuron.

to diffuse exterior light falling into the

galleries. Such a functional approach to
ornamentation is typical of many of the
projects by Herzog & de Meuron.
Patterned surfaces of the Federation
Square building in Melbourne (figure
2), designed by Lab Architecture Studio,
and are based on what is known in
mathematics as pinwheel aperiodic tiling,
enabling the designers to apply different
scales of the same pattern across the
building as needed. There are other
notable examples in which patterning is
based on mathematics. Daniel Libeskind,
for example, proposed a patterned skin
based on fractals for the extension he
designed for the Victoria & Albert Museum
in London.
In these, as in many other recently
completed projects, the patterning is
almost purely decorative, i.e. there is little
if any of the functionalist ornamentation
as seen in the work of Herzog & de
Meuron. A good example of this purely
decorative application of ornamentation is
the recently completed Ministry of Culture

Branko Kolarevic
Manufacturing Surface Effects

Figure 2. The pinwheel aperiodic tiling of the Federation

Square buildings in Melbourne by Lab Architecture
Studio.

and Communication in Paris, designed by

Francis Soler, which is wrapped in what
C.C. Sullivan (2005) referred to as technouveau latticework, a screen of stainless
steel with six recurring, symmetrical motifs
(figure 3).

Figure 3. Ministry of Culture and Communication in Paris

by Francis Soler.

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Working on a different scale of a single

panel, Bernard Cache also has explored
the decorative realm of pattern, texture
and relief, which seems to be the current
preoccupation of Greg Lynn (2004) too,
who, for example, in some of his recent
projects uses surface geometry to emit
texture information so that, like an animal
skin, the pattern and relief is intricate
with the form. Cache created parametric
CAD/CAM production processes in which
slight variations of parameter values,
either incremental and/or random, would
produce a series of differentiated yet
repetitive objects, called objectiles, each of
which would feature unique decorative
relief or cutout patterns, striated surface
configurations, etc. A particularly effective
technique was to exploit inherent
properties of the material, such as varying
coloration of different layers in laminated
wood sheets, to produce intricate
surface effects by CNC-milling relatively
small 3D curvilinear forms (figure 4),
thus introducing a certain economy of
production by reducing the amount of
machining and material waste.
Another, fairly recent trajectory in
contemporary architecture is to seek
out the unity of skin, structure, and
ornament (as a contemporary expression
of Vitruvius firmitas, utilitas and venustas)
through a digitally driven manufacturing
process that provides for variability in
volume, shape, texture and appearance
To that end, composite, layered materials,

Figure 4. Objectiles, designed by Bernard Cache.

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commonly used in automotive, aerospace,

shipbuilding and other industries,
are experimented with for possible
architectural applications, as they offer
the unprecedented capability to design
material effects by digitally controlling
the production of the material itself.
The composition of such materials can
be engineered precisely to meet specific
performance criteria, so that properties
can vary across the section to achieve, for
example, a different structural capacity in
relationship to local stress conditions, or
to vary fiber density to achieve different
opacity and appearance. By manipulating
material variables in composites for local
performance criteria, entirely new material,
tectonic and ornamental possibilities open
up in architecture.
Digital Fabrication and Surface
Effects
The different techniques of
manufacturing surface effects using digital
fabrication technologies were explored
in a four week project within an elective
course at the University of Pennsylvania
offered in the spring of 2005 and in the
fall at Ball State University. Students had
to define a parametric production process
in which slight variations of parameter
values, either incremental or random,
would produce a series of differentiated
yet repetitive ornamented objects,
featuring a combination of pattern, relief,
and texture. The produced objects were
then organized in a grid-like configuration
to produce a carefully choreographed field
effect. The objective was to investigate
potential figurative expressiveness of
(architectural) surfaces, i.e. their capacity
to communicate visually.

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Digital Making: Superficies: Integral and Applied

By working in groups of two, students

developed a geometric and manufacturing
logic for producing different instances of
a parametrically defined variable paneling
system, in which the size is fixed, but the
relief or cutout patterns can vary. The
emphasis was placed on the calculation
of curved and variable shapes and their
production using CNC tool paths precisely
crafted in software and executed on a
CNC milling machine.
Carmen McKee and Fuyuan Su
modeled a simple time-based parametric
process in Maya animation software that
resulted in different undulations of a
rectilinear surface. Isoparametric curves,
used in visualizing NURBS surfaces, were
extracted from selected frames and were
translated directly into CNC tool paths
for milling (figure 5a). The density and
number of isoparametric curves were
carefully explored, as were the sizes of
milling bits and whether the round or flat
ones should be used. Equally important
were the hardness and the texture of the
wood to be used in production. Thus, the
process was defined by parameters related
to the designed geometry, parameters
pertaining to production (such as the
size of the milling bit, the feed rate, etc.)
and parameters related to the material
itself, such as wood hardness, grain size,
etc. These parameters were interrelated
and numerous instances were explored
through several iterations informed by
continuous feedback loops between
design and production. In the end, the
panels were manufactured at the rate of
15 minutes per panel (each of which was
1 by 2 in size) and assembled in a linear
configuration (figure 5b).
The parameters that defined the
geometry of the panels designed by

Branko Kolarevic
Manufacturing Surface Effects

Figure 5a. Carmen McKee and Fuyuan Su used

Isoparametric curves directly as CNC tool paths.

Figure 5b. CNC-milled wood panels by Carmen McKee

and Fuyuan Su.

Jill Desimini and Sarah Weidner were

based on image processing techniques of
halftoning and motion blur. Images selected
from a video sequence were first halftoned
in Photoshop and then a motion-blur
filter was applied to the halftones,
resulting in what looked like a grayscale
image of an undulating surface (figure 6a).
These images were then imported into
Rhinoceros modeling software to define
the extent of deformation of a flat, meshed
square surface. The deformed surface
configuration was then used to compute
the milling paths in MasterCAM. As in the
previous project, the parameters related
to the production (size of the milling bit,
etc.) and the properties of the material
(texture, hardness, etc.) were crucial
to the overall success of the project, as

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Figure 6a. Image processing by Jill Desimini and Sarah

Weidner.

Figure 7a. Parametric weave by Virginia Little and

Maggie McManus.

Figure 6b. The field configuration of CNC-milled wood

panels by Jill Desimini and Sarah Weidner.

Figure 7b. Close-up of the parametric weave.

were the feedback loops between design

and production. After several, quick
iterations over four weeks, the final field
configuration of nine panels (figure 6b)
were carefully and quickly produced.
Virginia Little and Maggie McManus
also modeled a simple time-based
parametric process in Maya animation
software that resulted in slight, ripplelike undulations of a rectilinear surface.
Isoparametric curves were extracted
in both U and V directions from each
instance of the surface configuration, and
were then used as sweeping paths for
circular profiles of gradually increasing
radii. The resulting configuration of tubes
was cut with a flat plane, revealing the
internal voids in the tubes, and producing
an intricate surface effect (figure 7a).
That parametric weave was then

milled quickly in ordinary insulation foam

panels, which were then coated with a
layer of white hi-gloss latex house paint,
resulting in an intricate latticework screen
configuration (figure 7b).
Dustin Headley and Mickel Darmawan
were interested in carving out a complexly
shaped volume from a stack of layered
sheets, which were then spaced apart
to reveal the inner void (figure 8). The
outcome was quite surprising: if ones
eyes were to move along the side of the
resulting construct, a subtle, dynamic
effect emerged. The performative aspects
of the kinetic hyposurface, as named
by the students, were then fine-tuned by
exploring the different values for the key
parameters, such as the thickness of the
layers and the size of the spacing between
the layers. As was the case with previous

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Digital Making: Superficies: Integral and Applied

Figure 8. The kinetic hyposurface by Dustin Headley

and Mickel Darmawan.

projects, the parametric definition of the

geometry was fairly simple, as was the
production of the individual panels. After
several quick iterations, the (virtually
kinetic) result was more than a sum of
the (static) panels, which were carefully
arranged in a linear sequence.
Given that these explorations were
not conducted in a studio setting, but in
an experimental seminar focused on the
digital modes of production, a certain
economy of method was introduced
as a basic requirement for the project,
as in less effort, less machine time,
less material, less waste, which can
be summed up as less for more. As
illustrated by the projects described above,
not all students adhered to these design
and production demands. Nevertheless,
they were an important dimension of the
projects.
Appearance and Substance
Ornament shapes, straightens, and
stabilizes the bare arid field on which
it is inscribed. Not only does it exist in
and of itself, but it also shapes its own
environmentto which it imparts form.

Focillon(1992)
The projects and the ensuing
discussions centered on the perennial
questions of surface and form versus

Branko Kolarevic
Manufacturing Surface Effects

structure, of appearance versus substance

(or superficiality versus essence, as seen
by some) in contemporary architecture.
While the digital technologies of
parametric design and fabrication opened
new possibilities for non-uniform, nonmonotonous, variable patterning and
texturing of surface, the question of
appropriateness, i.e. of the cultural
significance of such ornamental treatment
of surfaces in a contemporary context also
emerged.
Following the famous manifesto
Adolf Loos published in 1908, polemically
titled Ornament and Crime, in which
he described ornament as a need of
the primitive man, arguing that the
lack of decoration is a manifestation
of a progressive, advanced culture, the
emergence of the Modern movement
entrenched a perception that to be
authentically modern, one has to
categorically remove all ornament,
which consequently led to the barren
surfaces of much of the twentieth century
architecture. It was the absence of surface
ornamentation that arguably made the
minimalist aesthetics of Modernism less
affectionate, contributing in part to
its demise. The facades did not shed
the rhythm and the patternbut their
monotonous grids did not give much to
the eye.
We took the Semperian position
that architecture comes to be defined
in its essence as an ornamental activity
(Semper 1863). After all, throughout
history (bar the second half of the
twentieth century) ornamentation was
used in buildings, both on the exterior
and in the interior, to enhance and amplify
presence and appearance, give scale and
texture through intricate treatment of

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surfaces, and demonstrate the mastery of

artisans and craftsmen. Ornamentation had
largely a symbolic functionit embodied
values and ideals that defined a particular
culture, simultaneously acting as a symbolic
construct and enabling construction of
symbolic meaning. Such an approach to
ornamentation is in line with the view
that the buildings are shaped by and are
expressive of the social, economic, political,
and cultural context, i.e. buildings are
representational, while simultaneously
being active agents in defining that very
same context.
Given the increasing presence of
ornamentation in contemporary design
(and not just in architecture but in a range
of design disciplines), an obvious question
to ask is if there is any deeper significance,
some kind of profound relevance of
ornamentation today. A possible answer to
that question could start with a definition
of what constitutes an ornament in a
contemporary context. As there are many
possible definitions, perhaps it would be
more appropriate to begin by making
some basic distinctions between different
kinds of ornament in architecture.
In general, ornamentation can
be decorative or applied, functional
or integral, and mimetic or imitative.
Ornament, when purely decorative,
relies on its application to an already
existing surface or an object; hence, such
ornamentation could be classified as
applied. Structural ornament is considered
an integral part of the buildings structure,
i.e. the structural components act
simultaneously as ornaments, as was the
case, for example, in gothic architecture.
Such ornamentation can be described
as functional or integral. Mimetic or
imitative ornamentation is characterized

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by unambiguous meanings or symbolic

significanceit is purely representational.
Today, however, when decorative is
used to describe an artifact, the meaning
is negative in most cases, suggesting that
the work itself is superficial, devoid on
any deeper meaning. The perception
of superficiality often stems from the
surface application of ornamentationit
is often seen as nothing more than an
(unnecessary) embellishment to an other,
as was the case for most of the twentieth
century.
When decoration is deployed in a
contemporary context, it is often used
to hide something unpleasant to the
eyea functional application that is
often judged as acceptable (Herzog & de
Meuron used an ornamented rain screen
to hide an integrated ventilation system
on the faade of the De Young Museum).
Decoration, however, is increasingly seen
as performative as well, as it can produce
effects that can directly affect an emotional
response; it can be excessive or minimal,
loud or quiet, serious or cheerful.
It can accentuate a specific quality of the
object or of the surface to which it is
applied.
Another way of understanding the
significance of ornament is to compare it
to pattern, which could be described as
an abstract construct characterized by
repetition. As such, patterns exist in nature
in all sorts of imaginable shapes, forms, and
sizes. It is only when a particular pattern
is recognized and represented in some
physical manifestation, such as decoration
for example, that it becomes a cultural
artifactan ornament.
The human need to perceive, organize,
and structure the world around us into
patterns and rhythms is seen as intrinsic;

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Digital Making: Superficies: Integral and Applied

decoration and ornament are recognized

as indicators of neurological synergy of
the eye and the brain. E.H. Gombrich
(1979) offers evolutionary arguments that
ornament is a result of a biological need
to generate underlying structure in the
surrounding environments: I believe that
in the struggle for existence organisms
developed a sense of order not because
their environment was generally orderly
but rather because perception requires
a framework against which to plot
deviations from regularity. According to
Gombrich, the human mind has an intrinsic
need for careful balance between
complexity and order. The mind has no
trouble deconstructing a simple, regular
grid (i.e. recognizing the monotonous); it
quickly disconnects in reading complex
configurations if it cannot recognize an
underlying structure. Gombrich argues
that a careful balance between these two
conditions, i.e. between monotony and
complexity, is what the mind looks for in
its constant processing of the surrounding
environments.
In other words, one could argue that
patterningor ornamentationis a
necessity, and perhaps as such, it should be
given back the significance it once had in
architectural discourse.

Note
This paper is based on a version
previously published in the Proceedings of
the Game Set & Match II Conference held
in March of 2006 at the Delft Technical
University in the Netherlands.

Branko Kolarevic
Manufacturing Surface Effects

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