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The following images show the concept and the process for laser cutting and fabricating a 3D waffle structured Bench as an assignment for our Digital Fabrication class.
This Bench is a collective design done by Ushma Nichani and Amay Gurkar.

The following images show the concept and the process for additively manufacturing a 3D Lego brick as an assignment for our Digital Fabrication class.
This 3D block is a collective design done by Ushma Nichani and Amay Gurkar.

Saiqa Iqbal, Xiomara Armijo

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.

One bench for two,

The idea was to have a street sofa with the possibility that two people will use it.

you can seat on the edge or seat like a king in you Neighborhood street sofa.

Checking the seats and Having reference for the size and direction

Modeling the surface with cage edit

The Y ribs – we make it in a way that some of the ribs go in one direction  of the assembly , and some on the other of it, so it will be an easier means; that some could be directed up and then the X ribs will be stand.

duygu kirisoglu // jesus zabala

The main idea is based on the usage of both sides of the bench. To do so, the bench has been divided into two in the middle. The form of the bench is generated mainly with plug-in called t-splines which allows to manipulate the surfaces smoother. In order to do that all the surfaces are converted to t-spline surfaces. Commands in t-splines such as manipulator, grip selection, smooth toogle etc are applied on the object. After the design is completed all surfaces are converted to rhino polysurfaces in order to make the ribs of the waffle structure. Contour command is applied in both x and y axis with different distances. Thereafter,  to have the notches on the intersection of the ribs’ surfaces, a grasshopper skript is used. Finally Project cplane command is applied on the surfaces to get all the pieces on the same level to print in lazer cutter.

Assignment 2: Laser cutter

By Carolina Aguirre and Carolina Miro

In addition to the challenge of 3D visualization introduced by the first assignment, this second assignment required the skill of decomposing a 3D design into 2D elements.  Furthermore, it was important to note that not only would our designs comply with certain boundary conditions, but also that the various designs were to be placed in continuation of each other, forming a fluid whole.

Starting out, control points were added to the provided element template in order for it to assume our unique design. As it was a polysurface, the command ‘cage edit’ in rhino provided us with a bounding box, which allowed us to manipulate the shape of the seating element. Many designs followed from the experimentation with the shape. However, our final design was chosen based on the criteria set both by the machinery to be used for the fabrication process, as well as the design purpose of creating a whole with the designs of other groups. The result was a dynamic, smooth element, providing a very welcoming, broad seating surface. The fluidity of the piece provided excellent prospects for successful fabrication as also its integration with the other designs.

After the 3D shape of the element was designed it was modified to be produced using the laser-cutting machine. The surface of the design was offset and contours created in both the x and y directions. Intersecting surfaces were made from these contours. Each intersection was modified by placing columns in the panels of each direction, which were placed and modified to create voids in the elements. This was done in order to be able to mount the panels once cut by the laser cutter. The intersection slots were made to be 2.8mm wide, creating a snug fit for the mounted panels. Lastly, the various pieces needed to be separated and projected, side by side, onto a cplane which had the same dimensions as the wooden panel to be placed in the laser cutter.

Once the 3D design had been translated into a 2D waffle structure, its file was exported to the laser cutter. A 3mm thick wooden plank was cut into the various waffle pieces. The cutting process was closely monitored in order to comply with the necessary safety precautions, such as ensuring that the cut pieces didn’t obstruct the machine while it was still in progress and of course to control a possible fire. After the pieces were cut successfully and without any incidences, these were assembled to produce the final product.

DESIGNERS’ CRITIC

Despite the bench was modeled with a sitting skeleton superimpose to have an idea of the human body proportion related to the bench, we don’t have the certainty that the curves correspond to the human ergonomics. The images with the human scales using the bench only shows the idea of how it could be used. We could have investigated more on the proper curvatures that the bench needed, or we could have played more with the modeling of the object but because of the early deadline we didn’t have the chance to do it. Despite, the idea and the general form is quite good, and the dense amount of ribs we gave to the bench emphasis the smoothness and simplicity of the object.