User:Understood12/sandbox/Kaynemaile Architectural Mesh

Kaynemaile is a modern chainmail fabric consisting of polycarbonate interlinked rings formed seamlessly together by liquid-state assembly to form a strong yet highly flexible mesh sheet. It is made from 100% high grade engineering polycarbonate.

Kaynemaile was invented by Kayne Horsham in 2004.

History
As Weta Workshop Artistic Director for the Creatures, Armor and Weapons department on The Lord of The Rings movie trilogy, Horsham developed a number of the Armor and weapons production processes, including the first light-weight, manually assembled, theatrical version of a historic 4:1 chainmail armour.

Initially Horsham researched and sourced traditional metal chainmail from India which was quickly identified as too heavy for the actors to wear or do stunts. He researched how the film industry had represented chainmail previously (like the painted knitted string used in the Monty Python movies). As a result, Peter Jackson and Richard Taylor challenged Horsham to create a chainmail fabric that looked and moved like real chainmail, but without the weight. Horsham directed a team of New Zealand based chainmail technicians to manually interconnect millions of polypropylene (PP) rings, coupled with developing a unique electroplating process that used deposition to apply pure silver—which was both a visual and practical way to hold these weakened PP rings together and produce the realistic looking chainmail armor used extensively throughout the LoTR movies and a number of later films. This process methodology was so successful that that this maile was incorporated into the costume design of characters like, Aragorn (played by Viggo Mortensen), Boromir (played by Sean Bean), the Gondorian race and Rohan armies, and most of the Orcs costumes incorporated some (justified by the fact Orcs are scavengers). This maile featured heavily in every battle scene and hero closeups due to the interesting light reflective qualities, it also offered a robust protective barrier during fights and stunts, adding dramatic movement to action scenes.

This work lead to the creation of a fully automated liquid-state injection molding fabrication process. The result is a 3D material made up of solid polycarbonate resin rings with no joints or seams in the links making the material much stronger. This inventive process and resulting materials was extensively patented and commercialized in 2006 under the Kaynemaile brand.

During filming of the LOTR films, the handmade chainmail was nicknamed “Kaynes-mail” initially by Viggo Mortensen (Aragorn) and then by the entire cast and crew. The Kaynemaile name stuck.

The first commercialized material is called Kaynemaile Architectural Mesh. This architectural material can be produced in unlimited size sheets, using a wide range of colors, materials and compositions.

Kaynemaile Ltd
Since the Lord of The Rings movie trilogy, Kaynemaile Architectural Mesh has been developed into a high performance mesh product, specifically for the Architecture and Design industry. The company, Kaynemaile Ltd, was co-founded in 2006 by Kayne Horsham and Robyn Downham.

Material Properties
Kaynemaile Architectural Mesh is an architectural material offering unique malleable attributes to form large architectural scale, 3D shapes or seamless screens. It is is possible to wrap an entire building in Kaynemaile as one seamless skin/façade. Kaynemaile has completed installations of seamless mesh facades that cover more than 1000m2 in one piece of material. No other material in the world can do this.

When combined with the high performance attributes of polycarbonate resin, the result is a dramatic lightweight and reflective, permeable membrane for buildings. It resists environmental elements, doesn’t corrode like traditional metal mesh does and is compliant to international fire standards. It is stronger and lighter than glass and is produced with 70% less energy than metal mesh. Kaynemaile is impact resistant making it suitable for many uses, both decorative and functional protective barriers.

Solar Reduction
Through independent testing, Kaynemaile mesh has proven to significantly reduces both radiant heat through direct sunlight (EMR) and thermal conductive heat from entering the interior of a building by up to 70%. This gives the material the ability to let sufficient daylight in yet manage the passive solar gain while maintaining visual transparency and reducing cooling costs and reducing energy consumption.

USA
Kaynemaile commissioned an independent fire code & engineering analysis of the USA building codes. This review was completed by the Fire protection dept, Jensen Hughes, USA. This review identified a total of nine NFPA and ASTM fire tests required for the Kaynemaile Architectural Mesh product to be considered “compliant with the 2015 Edition of the International Building Code (IBC) and NFPA 5000, Building Construction and Safety Code, 2018 Edition”. This review covered both interior linings and finishings and exterior cladding applications. Kaynemaile undertook both large and medium scale fire tests at the SWRI facilities in Texas and are proud to announce we have now successfully completed all the identified tests and are compliant with all these standards. Kaynemaile material and fixing system achieve a Class A rating.

BS EU, UAE, NZ, AU
Kaynemaile mesh and fixings meet USA NFPA and IBC code criteria for cladding and interior linings. Kaynemaile mesh has achieved a Group 1s in the ISO 9705 room test with a SMOGRA of 0.5m2/s2. UL94 FR-V0 material at 3mm that is rated self-extinguishing.

Applications
Kaynemaile Architectural Mesh has been used in many different final applications—from parking garage exteriors, solar shading and dividing screens in a workplace or retail spaces, and even large scale artistic kinetic applications.

Parking Garages
A 650-space parking garage will serve the Greater Columbus Convention Center in Ohio and features long sections of Kaynemaile mesh that moves with the wind. The parking garage is scheduled to open in February 2020 and was co-designed by Kinetic Artist Ned Kahn. Kaynemaile was used for solar screening on the parking complex of the $350 million redevelopment of Westfield Carousel in Western Australia which was completed in August 2018. The 27,500 square-metre expansion means at 110,000sqm, Carousel is now the biggest shopping center in WA.

The carpark at the newly redeveloped Pacific Fair Shopping Centre on the Gold Coast, Australia features a wave-like facade inspired by the world-famous beaches in the neighborhood. Kaynemaile collaborated with Scentre Group Design, to turn the carpark into a stunning, functional and highly visible landmark. The Pacific Fair Shopping Centre is the fourth largest shopping centre in Australia. Running the length of the shopping center’s 6500-space car park, the installation is considered to be the largest kinetic mesh façade in the southern hemisphere. Each of the 10 million, 28mm polycarbonate rings is strong enough to hold a person’s weight.

Eight individual Kaynemaile mesh screens were used to clad the Agostino Group parking garage in Adelaide, Australia. The largest of these individual screens was 58 meters wide x 16 meters high. With install speed in mind, the fixing systems allowed the large screens to be lifted and fixed in a day.

Residential Exteriors
Kaynemaile was used for solar screening on the Double Bay home designed by SAOTA Architects in association with TKD Architects which won 2018 TIDA International Home of the Year.

Adam Taylor, of Adam Taylor Architecture, won the ADNZ Resene Architectural Design Awards residential new home between 150m2 and 300m2 award for a Mount Maunganui home which utilized Kaynemaile for solar screening.

Commercial Exteriors
Exterior screens from Kaynemaile were used to create the façade of a walkway at the University of Auckland, New Zealand.

Progagonist café in Melbourne, Australia is wrapped in Kaynemaile mesh. Designed by Cumulus studio, the screen can be physically raised during the day while the café is open and lowered at night when closed. The mesh screen can also be used for projected graphics at night to market upcoming events. This project was the winner of the award for Small Project Architecture at the 2020 VIC AIA Architecture Awards. Protagonist café has also been shortlisted for Best Installation Design in the Eat Drink Design Awards 2020 in Australia.

Kinetic Installations
Artist Ned Kahn used Kaynemaile for the piece "Enagua" installed at Runway Playa Vista, California. Intended to suggest a garment, the artwork consists of a 100-foot tall oval-shaped tower that is wrapped in multiple layers of a plastic chainmail fabric that ripples in the wind like water.
 * 1) WAVExNYC a a 4.25 metre high, 40 square metre walk-though “touch and see” installation in New York's Times Square was designed by Kayne Horsham and Ned Kahn for NYCxDESIGN, New York City’s annual celebration of design. The one million interlocking rings forming the installation were created using Kaynemaile’s liquid state manufacturing process at its Petone, Wellington design studio and factory.

Lighting and Ceiling Features
Kaynemaile developed contemporary chandeliers made of Kaynemaile mesh for the lobby, dining and bar area as part of the West Plaza Hotel's $1 million upgrade in Wellington, New Zealand.

Interior Commercial
125 Murray Street Workplace used Kaynemaile’s Hanging Screen system in the foyer of this office redevelopment. This project was the winner of the Ross Chisholm and Gil Nicol Award in Commercial Architecture and received a Commendation in the Lighting Award at the 2020 WA Architecture Awards.

Awards
Architizer A+ Awards 2020, Product Winner in Facades-Building Envelopes & Cladding

2019 Architecture MasterPrize, Winner in Building Envelope & Construction Materials

Wellington Gold Awards 2018, Finalist Global Gold

Export Award (Innovation) 2017 – wellington chamber

NYCxDesign Award 2017, Best Architectural Product

designEX Award 2014, Best New Innovative Product

New Zealand Innovation Awards 2014, Highly Commended

New Zealand Plastics Industry Design Award 2008, Gold

Designpreis Halle Award 2008, Nominee

iF Design Award 2007, Discipline: Material