Category Archives: 3D Printing

3d Printing, Lego Brick

 Team: Javier González R. – Andrés Briceño G.

 

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Assignment 2: The Bench [lasercutted]

Hugo Carvallo + Viraat Kumar

Viraat

After experimenting with the first exercise -where we have to come up with a Lego brick design, we have involved ourselves into this new assignment, which is to design a small bench and fabricate it using a laser cutter.

During the process we look at different precedents where we learned more about parametric design of furniture.  We took a look at the ‘Parametric Couch’ designed by Seyyed Mohsen Hossainy, the ‘Chick ‘n’ Egg’ Chair designed by Manuel Kretzer of the group CAAD/ETH Zurich.

To carry you through the development of the bench in rhino…

Primarily we began with the curves and arranged the curves in a manner to get the correct curvature and bends.

Secondly, we lofted (loft) the contours to generate the  form, thereafter we contoured (contour) the bench with sections longitudinally and latitudinally.

On generating the contours we created a planar surface (PlanarSrf) for each contour and used the intersect command to get the intersection lines.

A pipe was created about the central axis of each line and projected upward and downward about the mid point of the intersection lines.

The pipes in the upward direction were intersected and trimmed with the latitudinal ribs and likewise the downward pipes with the longitudinal ribs, such that, the groove of the ribs interlock with each other.

The face edges of each surface was duplicated from the Curve<Curve from Objects<Duplicate face border option.

Each curve generated was grouped along with the rib number (to make identification and assembling easier). The Rhinonest plug-in was used to quickly organize the curves on the size of the plywood sheet. The file was then exported to the dxf format for laser printing.

The bench has multiple properties, it does not only can be used as a seating furniture, but also as a tool where students can interact and use it to place cups, cans or bottles, also the lower part is open for storage where backpacks, books, shoes,  and other objects can be placed.

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Lego brick – 3d printing



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3D Printing a Neurone Brick

Team: Julian Hildebrand & Manuel Huerta

View the:  Neurone Brick

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3D PRINT BRICK

                                 
TEAM: CARLO CALTABIANO & YASHASWINI APTE 

Concept:-  

Our 3D Print Brick pattern is inspired from the structure of a honey comb. However, the rigid hexagonal shape and the uniformity of the honeycombs have been modified integrating it with other polygonal shapes. These modules are varied in size and intensity to resemble a spider’s web. The idea was to read the voids as much as the solids akin to the Zaha Hadid’s ‘Mesa Table’ which was one of the case studies undertaken. To achieve a more organic form and to avoid rigidity, the surfaces have been gently curved.    

 

            +                =   

 basic module                                          spider web 

 

 
                     final derived brick pattern                   
 
 
           
Procedure for 3D Modelling:- 

Step 1: A single line polygonal pattern was drawn out which formed the basis of our 3D modelling. This was done by marking random points on the opened up surfaces of the brick. Using ‘Voronoi diagram’ a pattern was drawn out. This pattern was modified and redrawn to achieve the  required density required to balance out the solids and voids & to realise the spider web-like effect.

                   
positive surface                                                                      negative surface
 

 Step 2: We started with ’Pipe’. The 3d was drawn out using this and the next step was to join the overlapping surfaces. The larger polygonal surfaces were joined using ‘Boolean union’, the smaller ones did not get joined with this method. These intersecting surfaces would be a problem for the 3d printing & to maintain a honeycomb like section, we decided on a different approach.

Step 3: Polygons were drawn along the pattern & off-setted.  The negative spaces were then extruded using ‘extrude curve’. After which the rectangular face of one surface was extruded using ‘extrude curve’. The negative spaces of the extruded solid were then deleted using ‘Boolean difference’ creating the solid and voids. This was done for each face of the brick. 

Step 4: In this step the surfaces have been gently curved to achieve an organic appearance.  The surfaces thus obtained above were exploded using ‘Explode’ and then using ‘Rebuild’ the surfaces were modified along the control points.

 

                        Step 5:  After using ‘Rebuild’, each surface was grouped together. Using ‘c-plane’ the surfaces were rotated to form the outer surfaces of the brick.

Step 6:  The cylinder was made using ‘Tube’, this was exploded and converted into a mesh. To convert it into a solid the mesh was off-setted and using ‘Loft’ the inner and outer surfaces were joined.

Step 7: Boolean union did not work due to the thickness of the polysurfaces. To solve this the external surfaces were extracted using ‘Extractsurface’. this surface was copied out separately and meshed. the meshed surfaces was moved out and separated from the nurbs surface. The entire brick was joined together using ‘Join’ and then the mesh was off-setted to the required thickness. This created some naked edges when checked. We then decided to work on the cylinders separately. The surfaces without the cylinders were offsetted using ‘Off-set mesh’ and the previously done cylinder was exploded and then rebuilt. The surface of the cylinder was then curved along the control points, meshed, off-setted and then joined to the rest of the block.

Step 8: A check was undertaken to locate the naked edges, once we had confirmed there were no naked edges the file was converted to a .stl file for 3d printing.

 cleaning & sealing of the printed brick

 

 

 final printed brick

 

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Triangulated Brick

Team members:  Antonio Tamez y and Daniela Quesada Rivas

Process

We decided to begin with an agreed triangulation design fro the composition of the mass, and then individually experimented with different trial bricks:

The first dealt with the extrusion of curves to form poly-surfaces as the body and structure of the lego brick.  However this resulted in a bulkier configuration than originally envisioned, and we encountered problems boolean-joining the volumes.

The second approach was a deviation from the triangulation of the facade, but trying to maintain a structural web to the design, this time with curvilinear perforations.  This approach worked only for the sides of the brick, and we could not integrate the cylindrical parts of the lego into the design.

We returned to a triangulation of the structure of the bricks, so we could incorporated the cylinders and the voids into the overall vocabulary of the brick’s design.  The brick’s components were not joining properly and we had to add more elements to make it more structurally sound.

The final brick had the structural elements in a frame that composed the brick in its entirety, from the sides to the cylindrical tops and voids at the bottom.

Picking up the brick at the DHUB:

The brick was printed with 3 others in a batch.  As part of the process, it then had to be cleaned manually first, then with an air brush as a preliminary step.  The brick was sill in a fragile state so it was then doused in a strengthening solution before it reached a final rigid state.

Printed Brick:



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3d brick. ErinaFilipovska and LuzMichelleLavayen

Group: Erina Filipovska and LuzMichelle Lavayen


Assignment: 3d printing/ digital fabrication.


The inspiration for the 3d brick came from an Arabic pattern which we used to make the skin of the brick.

Since the pattern consisted lines and circles, we used that particular one to correspond to the shape of the brick which has flat surfaces and circled pipes. We started modeling the brick in Rhino, working on the separated surfaces which we made to be 3mm thick. We offset the lines of the pattern, joined all the lines, so we could have closed polylines in order to extrude them and make them solid. By Boolean difference we were able to make the desired holes in the 3mm surface.   Since the pattern is made to supplement itself, we used the basic one twice for the longer side and once for the shorter side. We copied the surfaces in order to make the whole skin of the brick. The circled geometric forms were designed to be where the pipes of the brick should have been, so we were able to use the form as a base of making the pipes.

Since this is a 3d printing model, we wanted to do something in the inside of the brick too. So using the places where the circles intersect the lines we made solid boxes connecting the circled surfaces inside the brick, from one side to the other but connecting the opposite points.

That way we got interesting structures inside the brick which can be seen throw-out the skin.

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3d printing – additive process study cases

AI. STOOL by Assa Ashuach

The AI.MGX stool is designed by Assa Ashuach and consists the first product to be designed using a combination of 3D tools and artificial intelligence. Produced by laser sintering, the chair consists of a cosmetic skin and intelligent soft and hard structures. Like the biological structure and mechanism of bone, the artificial intelligence software knows where to create sufficient support. The AI stool is an intelligent product that grows in free space with an artificial intelligence ‘DNA’ code. This code contains all of the information required to ensure that the object will transform perfectly from a virtual design into a 3D object that achieves the optimum strength or intelligent softness whilst maintaining the desired visual aesthetic. The AI.MGX stool was designed to carry a load of 120kg on a sitting surface at a height of 40cm. The challenge was to design a form with the minimum volume required for a seat and then instruct the AI software to calculate the required support. The final AI.MGX stool met all of the mechanical requirements while using only 1/3 of the anticipated material.

MELONIA SHOE by Naim Josefi and Souzan Youssouf

Melonia shoe is part of the catwalk collection “Melonia”, designed by Naim Josefi and Souzan Youssouf for the Stockholm Fashion Show in February of 2010. Five pair of shoes were designed in the modeling programme Rhinoceros 4.0 and were created using selective laser cutting, 3D printed in polyamide (nylon). Though seemingly not that solid, the shoes are actually firm enough to hold a normal adult thanks to their unique structure. They are the first 3D-printed haute couture shoes in the world and come as a result of the concept of no waste and rapid prototyping process. They are products for an industrial ecology that is based on the production and the easy recycling of such objects in a closed loop, due to their homogeneous material. Moreover, they follow the vision of shoe production that is for anyone to be able to go to a shop where he can scan his foot, choose the design and print his pair of shoes, which could after usage be recycled and reprinted into a new pair.

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Case Studies: Structural Skin

SEATTLE CENTRAL LIBRARY; OMA

The 34,000 sq. m. building has the capacity to house 1.45 million books, arranged in a non-conventional manner to entice visitors and promote physical books in a digital age. The spaces created by the wrapping skin house programmatic functions in four different floating platforms. The functions and their relationship to each other dictated the design of the building, and then a steel and glass skin was used to wrap and form the spaces, thus resulting in the unusual shape of the building, and the necessity for a structural skin. The circulation flows through the different spaces that overlap each other visually, though not always on the same plane of elevation. The structural façade facilitates this by allowing a suspension of different spaces, and allowing visual permeability through the design of the structure.

source: archinet.com

source: oma.nl

source: stgb.blogspot.com

TOD’S, OMOTESANDO; TOYO ITO

A building designed to house the high end Italian shoe retailer, it is distinctly a project that uses its structural façade to stand out from its surrounding retail architecture. With a limited frontage on an important retail street, the building needed to make a visual statement without relying on excessive storefront display. The entire skin of the building was used to create a visual identity. The structural concrete and glass skin in conceptual form is an abstraction of the trees that line Omotesando street. The façade serves a second purpose, being a structural element, it frees the interior spaces from the need of columns, or load bearing interior walls. The interior paces are therefore more freely designed without any additional constraints to what is already a narrow footprint to work with.

source: archrecord.construction.com

source: artisticstation.blogspot.com

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Case Studies

CASE STUDY I – MESA TABLE

 

 
 
 
 
 
 
 
 
ARCHITECT/ DESIGNER: Zaha Hadid with Patrick Schumacher 

PROGRAM: Mesa Table for Vitra 

MATERIALS: Polyurethane base, Fiberglass top, Metallic paint finish  

The Mesa table has evolved from an architectural experiment by Zaha Hadid which was to do with creating connections. The ideology goes back to the basic components of ground, structure, surface and creating a world with extruded connections between these two horizontal planes. These connections become the structure of the table. The outcome is a ski-fi like structure where the voids express the form as much as the solids. This sculptural creation appears elastic stretching out to form the supporting base of the table. It is an amorphous, fluid, flowing, delicate and at the same time tenacious base structure. While the top of the table is composed of four separate triangulated components, they are ably connected with the polyurethane ‘tentacles’ to form an organic composition. The chosen materials successfully achieve in the realisation of the envisaged flowing form and concept. (Source for images & reference of text:  http://www.design-art-book.com/2008/05/table-mesa-vitra-de-zaha-hadid.htmlhttp://www.zaha-hadid.com/furniture-product-design/mesa )

  

  

  

  

  

  

  

  

CASE STUDY II – VILLA IN KITASAKU, NAGANO, JAPAN  

 

 

 

 

 

 

  

ARCHITECTS: Kotaro Ide / ARTechnic architects

PROGRAM: Villa

MATERIAL: Concrete shell structure

The villa consists of a large shell shaped structure positioned in the middle of the woods. The shell enclosure forms the roof, floor and external wall of the house. Stemming from a desire to design a place that would be in sync with nature, the architects envisioned a large shell structure floating above ground. The use of concrete and lifting of the structure has effectively aided in dealing with the humidity in the area. The entire structure is composed of a two dimensional curved surface wherein the larger mass opens up higher along the convergence of the two masses. The J shaped structure consists of different size oval cylindrical masses cut with curves in the central portion of the structure. The straight part of J, a smaller mass is connected to the curved part of J, a larger mass. The concrete shell thickens and its width increases towards the side of the building to take care of the structural requirements. The floor is raised above the ground, with the lower half of the shell structure protruding greatly towards the outside, supporting the terrace at the same height. The curved shells have minimal openings consisting of two circular skylight punctures at the top to allow the flow of natural light, thus maintaining and emphasising the solidity of this main structural element.  (Source for text and images: http://www.archdaily.com/11602/shell-artechnic-architects/ )

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