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Fabrication Process

TrussFab

https://prostheticknowledge.tumblr.com/post/159941407051/trussfab-computer-aided-design-project-from-the

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Software

Designing Structurally-Sound Ornamental Curve Networks

We present a computational tool for designing ornamental curve networks—structurally-sound physical surfaces with user controlled aesthetics. In contrast to approaches that leverage texture synthesis for creating decorative surface patterns, our method relies on user-defined spline curves as central design primitives. More specifically, we build on the physically-inspired metaphor of an embedded elastic curve that can move on a smooth surface, deform, and connect with other curves. We formalize this idea as a globally coupled energy-minimization problem, discretized with piece-wise linear curves that are optimized in the parametric space of a smooth surface. Building on this technical core, we propose a set of interactive design and editing tools that we demonstrate on manually-created layouts and semi-automated deformable packings. In order to prevent excessive compliance, we furthermore propose a structural analysis tool that uses eigenanalysis to identify potentially large deformations between geodesically-close curves and guide the user in strengthening the corresponding regions. We used our approach to create a variety of designs in simulation, validated with a set of 3D-printed physical prototypes.

www.disneyresearch.com/publication/designing-structurally-sound-ornamental-curve-networks/

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Fabrication Process

felix raspall + carlos bañón installs 3D-printed fibrous pavilion at SUTD singapore

http://www.designboom.com/architecture/felix-raspall-carlo-banon-vmesh-pavilion-sutd-singapore-open-house-06-21-2016/

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Fabrication Process

Active Structures through Auxetics

Auxetic structures possess negative Poisson ratios, i.e. when stretched in one direction, they tend to expand in the other two as well, and vice versa. We aim to exploit this in activating 3d printed multi-material structures.

Description

Auxetic structures have a negative poisson ratio, i.e. when stretch in one direction, it expands in the other directions, and vice versa. Typically, existing auxetic structures are defined by tiling of repeating auxetic unit cells. More recently, homogenization methods have been applied to the optimization of 2D and 3D unit cells, see section 2.10.2 of [1]. Though only one geometry can be generated for a given ratio.

[1] Bendsøe, M. P., & Sigmund, O. (2004). Topology optimization: theory, methods, and applications.

Goal

We would like to see if it is possible to convert any convex polyhedron to its re-entrant version and effec-tively reverse its Poisson ratio. Then, we would like to see if auxetic mechanisms may be used in the design of deployable active structures.

The goals include

  • Review of 3D auxetic unit cells and tessellations based on their poisson ratio
  • Design auxetic cells & tessellations for active structures
  • Fabricate and measure the Poisson ratio
  • Formulate an optimization problem which maximizes material’s Poisson ratio

https://siropglobal.org/app/opportunity/145c43b3-6cf1-4d36-a2df-0121969480b0

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Fabrication Process

Waffle slabs

Alarcon+Asociados

Waffle slabs have been around for a while; John B Parkin’s brilliant and beautiful Toronto International Airport Terminal 1 was built from them. Unfortunately they are also difficult to repair; when salt got into the steel the whole thing started disintegrating. They don’t have that problem in Spain.

By putting holes through the web of the waffle, the services are integrated into the depth of the slab. This permits a reduction of exterior façade per floor of 10% to 20%; the use of waffles in the first place reduces the number of columns or load bearing walls by 10-20%. It adds up to greater efficiency and energy savings. Because waffle slabs look good and break up sound reflections, you can also save on suspended ceilings.

http://www.treehugger.com/green-architecture/holedeck-waffle-slab-construction-system-saves-20-floor.html

http://alarconasociados.virb.com/logytel

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Fabrication Process

Insulated Concrete Forms for Floors, Roofs and Tilt-Up Walls

Ideal for both residential and commercial construction, INSUL-DECK buildings are not only more comfortable, quieter and super energy efficient, but also provide safety from hurricane level winds, fire and floods.

http://www.insuldeck.com/insulated-concrete-floors/

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Fabrication Process

Not just Doodling – Using 3D Printing Pens as a Design Tool

There might be a perception that 3D printing pens are for doodling and crafting but several designers are using general purpose and customized pens for something completely different. Recently, architect Kengo Kuma led a group of University of Tokyo students in an installation (up top) created with a custom 3D printing pen they designed (above). The pen is used to create architectural structures by linking acrylic rods using the melted filament in the pen. These structures are intended to last for 9 months or so, but can be enhanced and reinforced continuously with more filament connections (see detail below).

http://www.makeitleo.com/blog/not-just-doodling-using-3d-printing-pens-design-tool/

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Fabrication Process

World’s First and Fastest 3D Printed Jet-Powered Drone Cuts Production Time 50%

For the wings, the high-strength ULTEM thermoplastic was chosen. Manufactured using Stratasys Fortus FDM 3D printers, the wings feature a very lightweight honeycomb structure. As with the aircraft’s center support structure, the wings were designed with integrated pathways for wiring.

http://www.caddedge.com/stratasys/3d-printing-blog/worlds-first-and-fastest-3d-printed-drone-using-fdm

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Fabrication Process

Carbon-fiber epoxy honeycombs mimic the material performance of balsa wood

As turbine makers produce ever-larger blades—the longest now measure 75 meters, almost matching the wingspan of an Airbus A380 jetliner—they must be engineered to operate virtually maintenance-free for decades. In order to meet more demanding specifications for precision, weight, and quality consistency, manufacturers are searching for new sandwich construction material options.
Now, using a cocktail of fiber-reinforced epoxy-based thermosetting resins and 3D extrusion printing techniques, materials scientists at the Harvard School of Engineering and Applied Sciences (SEAS) and the Wyss Institute for Biologically Inspired Engineering have developed cellular composite materials of unprecedented light weight and stiffness. Because of their mechanical properties and the fine-scale control of fabrication (see video), the researchers say these new materials mimic and improve on balsa, and even the best commercial 3D-printed polymers and polymer composites available.

https://www.seas.harvard.edu/news/2014/06/carbon-fiber-epoxy-honeycombs-mimic-material-performance-of-balsa-wood

https://www.sciencedaily.com/releases/2014/06/140625151548.htm

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Fabrication Process

Arc Bicycle: 3D printed steel bike

In a three-month project a bicycle frame has been designed by team of students from the Netherlands’ Delft University of Technology to showcase the potential of the printing specialists MX3D of Amsterdam and their method of printing metal by three-dimensional means. Development of the ‘Arc Bicycle’ is part of a research project at AMS Building Fieldlab, and involved use of multi-axis robotic arms to 3D-print the frame. As Harry Anderson of the design team states, “The topic of 3D printing has exploded in popularity over the last decade, but the technology still comes with significant limitations for those wanting to print medium- to large-scale objects. The MX3D method of 3D printing now makes it possible to create large metal objects with almost total form freedom”.