#hbra architects

[davidbrussat]

Tale of two library entries Here is last month's blog post for Traditional Building magazine. It applauds a recent Palladio Award winner, HBRA Architects of Chicago, for reopening a library entrance at Northwestern University that was closed in 1970 after a Brutalist new library was built.

[obrienmetal]

Digital metal fabrication: Age-old craft meets cutting-edge technology – turning computerized visions into reality.

When most of us think about metalworking, images of workers beating red-hot rods with ringing hammers, hell-hot forges, and molten liquid pouring from huge looming buckets come to mind.  But gone are the days of the dark, dingy sweat shops with craftsmen in leather aprons shearing, welding and pounding away to wrestle works of art from metal through heat, talent and sheer brute force.

Technology is molding the future.

A new breed of metal fabricators is on the forefront of a digital revolution of technology and artistry that is evolving at a dizzying pace. Take, for instance, O’Brien Metal, Inc. in Chicago’s Lincoln Park.  Their high tech and spacious fabrication and finishing facility bears little resemblance to the black caldrons of old movies and industrial films. Improved methods and processes allows for even the most intricate work to be done to the most exacting standards in a fashion that’s easily repeatable, using state-of-the-art digital mapping, computer-aided dimensional design, and virtual cast engineering.  The more crucial the piece to an architect’s or designer’s vision, the less room for error. 

At O’Brien Metal, most pieces begin in the virtual world of 3D CAD (computer aided design), where ideas come to life and options are explored without ever casting a single mold.  Here, in-house architectural detailers work side by side with metal artisans, mold-making and casting professionals, and creative patina specialists and rely on the new tools of track pads and high-def monitors as much as their predecessors did on the hammer and anvil.

“We have integrated high tech into traditional metal fabrication – replacing a lot of cumbersome and time-consuming processes. Modern day tools and techniques allow us to work faster, smarter and more efficiently, while still crafting luxury furnishings that are timeless,” said John O’Brien, owner of O’Brien Metal.  “We use technology to improve efficiency and enable a more fluid design-build approach – all the while remaining true to the architects’ vision. We’re now partnering with architects and designers early in the process to rapidly help evaluate feasibility and engineer solutions that will far exceed customary functionality, usability, and aesthetic goals.”

Everything old is new again.

Take for instance this highly ornate corner section for a new custom historic bar cart.  Chicago’s HBRA Architects wanted to capture the timelessness of intricate bronze and silver details, with equal scrutiny on how these precious metals would embellish an integrated, highly polished black veneer. CAD modeling was used to produce 3D plastic resin printouts that serve as initial casting patterns. The patterns are then used to create silicon bronze castings inlaid with jewelry quality silver filigree.

When Dirk Denison Architects of Chicago and New York wanted a show-stealer for a client’s dining room, they envisioned an aluminum structure that would support a generously proportioned, sustainable resin top.  Digital 3D CAD modeling was used to produce a 3D plastic resin printout that served as the initial pattern to create cast aluminum dining table bases.  The need for absolute precision was influenced by the structural properties of the multi-radius table base design.  Tight tolerances for the radii had to be kept in order for the base to properly support the LightBlockstm top.

This ornamental grillage and frieze design was specified for a landmark home designed by Eric J. Smith Architects in New York.  Forged from the latest techniques and processes, these intricate ornamental silicon bronze panels look as if they were crafted more than a hundred years ago. Back then, it was a tedious process of hand work and sweat equity.  Instead O’Brien Metal used detailed CAD drawings to replicate the pattern, and water jets to cut entire grillage & frieze panels – bypassing the need to make molds and then extensively chase and grind away any imperfections by hand.  Any size grille can be made at the push of few computer keys, rather than starting anew for each new size.  Then final panels were then hand etched to give them character and finished with a rich historic patina to create an aged bronze appearance. 

Very few in the United States are capable of achieving the type of detail and quality O’Brien Metal can. 

“They are masters at stripping back the ideas to help uncover the how behind the design inspiration. O’Brien Metal is changing the game on their competition and takes a highly intelligent and refreshing approach, unlike traditional cumbersome metal shops that are frequently difficult to work with and produce lackluster results. They are smart, talented, fun to work with and produce the high quality results our clients demand, “ said Aric Lasher, Architect Principle, Director of Design, HBRA Architects.

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish.  Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York.  The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals.  They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442.  O’Brien Metal is located at 2100 N. Southport Avenue in Chicago’s Lincoln Park.