Workshop 1 _ Clay 3D Printing , AADRL

HAZEL OZRENK|SULTAN ALMUTAIRI|PAVLOS SYMIANAKIS|HAMZE MACHMOUCHI

WORKSHOP I | CLAY PRINTING

Contents Clay Ingredients

6

End Effector B01 Design

8

End Effector B02 Design+ Manual Prints

10

End Effector B02 + Nachi Prints

12

End Effector B03 + Kuka Prints

18

Topology Iterations

20

Column Design

27

Joint Mechanism

30

Printing Catalogue

Clay Mix Ingredients Too Wet 1000 g 100 ml None

Manual + End effector B01 Mixture 1 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Dry Too Fast 1000 g 60 ml 5 Drops

Manual + End effector B02 Mixture 1 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Good Result 1000 g 100 ml 5 Drops

Mixture 3 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Better Result 1000 g 100 ml 10 Drops

Mixture 3 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Good | Wet 2000 g 200 ml 20 Drops

Natchi + End effector B02 Mixture 1 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Best | Balanced 3000 g 300 ml 15 Drops

Mixture 2 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Too Wet 2000 g 200 ml 20 Drops

Kuka + End effector B03 Mixture 1 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

Best | Balanced 3000 g 300 ml 15 Drops

Mixture 2 Nylon Reinforced Air-Dry Clay / New Clay Water Sodium Dispex

End Effector Design Over the course of the workshop we have developed both a manual and semi-mechanical method for additive clay printing.

Using the manual end effector revealed dificulties with the line accuracy and pressure consistency.

Our end effectors for the robot arms are pressurized in order to provide a consistent extrusion during the execution of our generated toolpaths.

Based on the clay mixtures that were tested, we were able to develop a series of prints that can stack on top of each other in order to achieve height

Figure pneumatic end effector B02

25mm

290mm

HANDLE

ROD

32mm

CAP

24mm

PISTON

330mm

TUBE

33mm

78mm

1st Print with End Effector B01

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2nd Print with End Effector B01

SCREW

NOZZLE

End Effector B01

1st Print with Manual End Effector B02

2nd Print with Manual End Effector B02

3rd Print with Manual End Effector B02

4th Print with Manual End Effector B02

End Effector B02

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Pattern Experimentation

Emerging Topology

5th Print with Manual End Effector B02

6th Print with Manual End Effector B02

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7th Print with Manual End Effector B02

Branching

7th Print with Manual End Effector B02

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Nozzle

PVC Coupler

PVC Reducer

PVC Coupler

Metal Rod

Acrylic Pipe

PVC Coupler

MDF Lazer Printed Connector

MDF Lazer Printed Housing PVC Reducer

Brass Reducer

MDF Lazer Printed Housing

Valve PVC Adapter Nozzle

Nachi + End Effector B02

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Gradient, Geometry & Branching Experiments When we transitioned from Manual to Robotic extrusions, we had the desire to create intricate shapes. Our first insinct was to investigate bifurcation. After multiple failures due to pressure control, we decided to make height our priority. In order to achieve height, we decided to extrude first simple geometries

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1st Print with Nachi End Effector B02 Material Testing |Gradient

2nd Print with Nachi End Effector B02 Material Testing | Angle

3rd Print with Nachi End Effector B02 Air Pressure Testing | Bifurcation

4th Print with Nachi End Effector B02 Material Testing | Gradient + Pattern

Taller + Wider Prints with Nachi Our test of simple geometries revealed to be successful up to a certain height and width. We then decided to opt for more culvinear form to add structural capailities to our objects

5th Print with Nachi End Effector B02 Geometry Testing | FRep Method

6th Print with Nachi End Effector B02 Geometry Testing | Tall Geometry

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Complex Geometry Prints with Nachi

7th Print with Nachi End Effector B02 Geometry Testing | Tall Geometry

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8th Print with Nachi End Effector B02 Geometry Testing | Complex Geometry

9th Print with Nachi End Effector B02 Geometry Testing | Complex Geometry

Joint Testing | Assembly of Two Model

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Nozzle

PVC Coupler

Acrylic Pipe

PVC Coupler

PVC Reducer

PVC Adaptor Nozzle

Kuka + End Effector B03

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Prints with Kuka

7th Print with Nachi End Effector B02 Geometry Test | Structurally weak Design

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8th Print with Nachi End Effector B02 Geometry Test | Overheated and shrank

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Topology Iterations

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Topology Iterations | FRep

1st Form Generation with FRep Method From Generation | Conservative Approach

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2nd Form Generation with FRep Method From Generation | Simple Footprint

3rd Form Generation with FRep Method From Generation | Increasing control points to generate more complex geometries

4th Form Generation with FRep Method From Generation | In order to print tall column we increased the inner folds

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Final Column Model | FRep

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Column Design 25 || TEAM YNI

Final Geometry Plan

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Horizontal Iso Curves

Part A Bottom Iso Curve

Part C Top / Part D Bottom Iso Curve

Part A Top / Part B Bottom Iso Curve

Part D Top / Part E Bottom Iso Curve

Part B Top / Part C Bottom Iso Curve

Part E Top Iso Curve

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Joint Mechanism

Part E

Acrylic Ring Joint Bolts

Part D

Acrylic Ring Joint Bolts

Part C

Acrylic Ring Joint Bolts

Part B

Acrylic Ring Joint Bolts

Part A

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Printing Catalog

Part A

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Part B

Part C

Part D

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Model Assembly

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