Digital Fabrication

MAA 2010-2011, IAAC

The project was about to transform a given Lego Brick of specific dimension by using the software Rhinoceros as a modeling tool to print it by the 3d printer. The cylinders and the 8 corners was to be fixed for using each brick to join with each other as lego blocks.

Our aim was to create a structural skin which would hold a different entity inside. We wanted to design a form consisting object inside object to explore the 3d modeling advantage of the 3d printer.

Modeling the Brick in Rhinoceros _

1^st step_ we divided the 6 surfaces of the given brick with 3 mm grid to ensure the minimum thickness for the 3d printer.

2^nd step_ we wanted to give the surface the visual quality of a porous material. So we draw the surfaces with closed curves of varying dimensions. For having a different element inside, we draw some circular surfaces in the void spaces among the closed curves.

3^rd step_ for the objects inside, we had run the command loft by selecting the 2 circular shapes drawn on the surfaces of opposite directions. We created the lofts in both x and y directions.

4^th step_ we capped the lofts in both directions to have solid pipes.

5^th step_ we meshed all the solid pipes.

6^th step_ for the structural skin, we had run the command of planar surface by selecting each surface and its corresponding closed curves to get a porous surface.

7^th step_ we joined all the surfaces of the brick to convert it into one object.

8^th step_ we meshed the external surface.

9^th step_ we extruded the meshed surface in internal direction with the thickness of 3mm.

10^th step_ we had run the command Boolean union by selecting the external skin with each of the solid pipes to make the two objects to act as one object.

11^th step_ we exported into STL file as a final step for printing.

Using the 3d printer_

_  after completion of the printing, we brushed the extra powder from the external surface of the brick. Then we further cleaned the brick with a small air machine to clean the delicate crissed-crossed object inside.

_  then as the final step we sprayed fixer over the brick to have a durable form.

A masters project for a group of postgraduate students of Computer Aided Design (CAAD) at ETH Zurich, Switzerland, m.any was realized during a three month period. Intertwined with the programming process, construction studies and fabrication systems were developed. Using construction data directly derived from the 3D-model, m.any variations could be explored and tested. Using a combination of JAVA and RhinoScript, the group were able to generate, test and prototype the design process ensuring that it met the assessment criteria. 3D printed models were created during initial visualizations, followed by laser-cut, component based models.

The final and realized spatial structure consists out of 1500 individual parts all generated and produced in a seamless digital workflow. 111 main assembly frames were CNC milled, and precisely 1368 MDF connection pieces were laser-cut. In total 34 hours were spent in the workshop cutting all of the pieces, in addition to 16 hours of installation and construction time within the gallery.

(http://peterbooth.wordpress.com/category/casestudy/page/2/)

Christina Doumpioti
Architectural Association, Emergent Technologies + Design

The core idea of this research is the incorporation of the morphogenetic principles found in natural systems in the generation of fibre-composite structures by exploiting, at the maximum, the intrinsic performative capacities of the material system in use. The intention is the integration of form, material, structure and program into a multi-performative system that will satisfy simultaneously several, even conflicting objectives, in order to achieve an optimal compromise. This process involves the combination and implementation of concepts and methods based on precedent studies in the field of biomimetics, as well as form-finding digital and physical experiments that inform a coherent design methodology, leading to a structural system able to be fabricated using cutting-edge technology.