DESIGN FOR MANUFACTURE
SKILLS PORTFOLIO 2018 - 2019
ALFREDO SALGADO FERRER
BARC0074
ALFREDO SALGADO FERRER 2018-2019
CONTENTS
Skills Portfolio
1 RHINO
- 3D modelling interface - Documentation of modelling process - Developments - Final outcomes
2 FUSION 360
- 3D modelling interface - Documentation of modelling process - Developments - Final outcomes
3 VIDEOGRAPHY
- 3D modelling interface - Equipment - Storyboard of ďŹ lm - Final Outcomes
4 WORKSHOP
- Drawing interface - Processes - Final outcomes
Index
Skills Modules
ALFREDO SALGADO FERRER 2018-2019
1 RHINO
- 3D modelling interface - Documentation of modelling process - Developments - Final outcomes
1.
Skills Portfolio
ALFREDO SALGADO FERRER 2018-2019
RHINO 6.0
Software Interface
Window title : Displays the current model's ďŹ le name. Menu : Groups Rhino commands by function. Command history window : Displays previous commands and prompts. Command prompt : Type commands here. Command options are also displayed here. Toolbar : Graphical icons for initiating commands. Viewport name : The name of the viewport , which can be saved or loaded . Left click to activate the viewport; right click to display the viewport menu. Viewports : The main Rhino working environment where objects are displayed and selected . Status Bar :Displays the current coordinate system, the current location of the cursor, and the status bar panes
Rhino 6.0 is a powerful NURBS and meshes modeller capable of accurate precision, high levels of interaction with other formats and contains a vast array of plugins available. The interface now has Grasshopper embedded, which allows new parameters for design and ways of visualization.
Fig1. Screenshot of Rhino 6.0 Software interface.
Rhino
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Software Interface
Window title : Displays the current model's ďŹ le name. Operations menu: contains alternative plugins for Grasshopper. Menu : Groups Grasshopper commands by function. Component panels.
Canvas toolbar. The canvas.
Components/commands.
Grasshopper is graphical algorithm editor tightly integrated with Rhino’s 3-D modelling tools. Unlike RhinoScript, Grasshopper requires no knowledge of programming or scripting, but still allows designers to build form generators from the simple to the awe-inspiring. During the skills module, we studied other several plug-ins for Grasshopper, such as Karamba, Kangaroo, Weaverbird, Robots, Lunchbox amongst others.
Fig1. Screenshot of Grasshopper software interface.
Rhino
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Distorted Bricks - Wall example
Inputs for definition of Brick Geometry. Curve 1 for layout of bricks. Curve 2 for layout of bricks. Box collection of brick components. Selection of brick centre plane. Generation of a plane for location of surface. Generation of a Surface. Surface deformation by an image of a pattern of random lines. Angle of Rotation for deformation.
Throughout this exercise, we wanted to achieve a parametric design which would enable to modify several parameters of a common brick wall by managing the inputs of the definition such as: the geometry of the brick, the length, and height of the wall. Later a deformation was applied by rotation of the bricks through their geometrical centre to an image sampler in order to achieve a specific pattern on the final outcome.
Fig1. Screenshot of Grasshopper interface with definition of brick wall type. Fig2. Front and perspective views of brick wall type.
Rhino
Modelling Process
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Voronoi wall example
Generation of a plane surface. Creation of Voronoi Lines. Generation of Voronoi surface. Transformation of the surface using Weaverbird Catmull Clark components.
The partitioning of a plane with points into convex polygons such that each polygon contains exactly one generating point and every point in a given polygon is closer to its generating point than to any other. A Voronoi diagram is sometimes also known as a Dirichlet tessellation.
Fig1. Screenshot of Grasshopper interface with deďŹ nition of Voronoi wall type. Fig2. Front and perspective views of Voronoi wall type.
http://mathworld.wolfram.com/VoronoiDiagram.html
Rhino
Modelling Processes
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Tiled Surface example
Generation of Grid. Transformation of Grid. Tile Unit Geometry. Grid division and rotation. Tile Unit to surface. Position of wall (move).
Tiled surfaces can be very interesting when applied to a free form surface, the changing planes of origin for the tile unit can cause deformations. This deďŹ nition from grasshopper enables a surface to be deformed randomly and still maintain the attributes of the geometry of each individual tile component without losing the shape of the base surface.
Fig1. Screenshot of Grasshopper interface with deďŹ nition of tiled surface. Fig2. Front and perspective views of tiled surface.
Rhino
Modelling Process
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Structural Canopy Example
Generation of the surface plane. Generation of the canopy structure (grid). Selection and projection of the points for columns. Loft for the canopy. Pipe for Canopy (structure). Thickness of the Canopy. Position of Canopy (move). Columns (projected points).
The canopy structure definition was generated as an example to demonstrate the Karamba analysis. However, this example also allows us to study how modelling of tessellated patterns can be achieved in Grasshopper. With the cull pattern command, the interface allows you to select specific point on the surface and project them or move them to another plane or make connections with two points.
Fig1. Screenshot of Grasshopper interface with definition of Canopy type structure. Fig2. Top, Front and Perspective views of Canopy type structure.
Rhino
Modelling Process
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Karamba - Analysis
Karamba is a plugin for Grasshopper which contains diverse commands that enable the structural analysis of a section of a certain material submitted to a speciďŹ c load. From a structural deďŹ nition generated in Grasshopper, the analysis of Karamba demonstrates in a graphic way, the behaviuour of a structure to the load it is tested with and whether the parameters for section and material are the appropriate ones.
Fig1. Screenshot of Grasshopper Software interface for Karamba Analysis. Fig2. Screenshot of Graphic Karamba Analysis Display.
Rhino
Developments
ALFREDO SALGADO FERRER 2018-2019
GRASSHOPPER
Final submission - Pavilion
Bake is a command which allows Grasshopper coding parameters to be transformed into surfaces and solids in the Rhino software interface. These solids can then be managed in rhino. This images from the ďŹ nal submission for the Rhino Grasshopper assignment are a mere demonstration of the renderer command from rhino, which enables us to attain a quick visualization of a Grasshopper outcome.
Fig1- 4. Rhino Rendering of Baked Grasshopper submission for Parametric Pavilion.
Rhino
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
RHINO 6.0
Model of OEUF
Modelling in Rhino enables a lot of possibilities both in precision and complex morphological achievements. Rhino 6.0 models can be rendered in V-ray and other Rhino plugins which can give a photorealistic output.
Fig1-3. Process Modelling and ďŹ nal output render for Rhino 6.0.
Rhino
Model Final Outputs
ALFREDO SALGADO FERRER 2018-2019
2 FUSION 360
- 3D modelling interface - Documentation of modelling process - Developments - Final outcomes
2.
Skills Portfolio
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Software Interface
Application bar Profile and help: Controls profile and account settings. Toolbar: Helps to select the workspace to work in, and the tool of choice in the workspace selected. View Cube: Aids to orbit your design, or view the design from standard view positions Browser: Lists objects in the design. it can be used to make changes to the objects Canvas and marking menu: Left click to select objects in the canvas. Right-click to access the marking menu. Timeline: Lists operations performed on your design. Right-click operations in the timeline to make changes. Navigation bar and display settings: Contains commands used to zoom, pan, and orbit the design.
Fusion 360 has three main criteria: Design: Quickly iterate on design ideas with sculpting tools to explore form and modelling tools to create finishing features. Engineer & simulate: Test fit and motion, perform simulations, create assemblies, make photorealistic renderings. CAM: Create toolpaths to machine your components or use the 3D printing workflow to create a prototype.
Fig1. Screenshot of Fusion 360 Software interface.
Fusion 360
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Equipment for CNC
EM: Roughing / Flat / Vertical Surfaces. DC: Roughing / Flat / Vertical Surfaces (wood). BN: Roughing / Sloping Surfaces. Endmill (EM) Endmill (EM) Upcutter Downcutter Ø 1, 2, 3, 4, 6, 8, Ø 3, 6, 12 mm 10, 12, 16, 20 mm
Ballnose(BN) V-Cutter(VC) Cutter Ø 6mm Ø 1, 2, 3, 4, 6, 8, 10, 12, 16, 20 mm
Spot Drill (SP) Ø 8, 16mm
Drill (DR) Ø 1-12mm
VC: Engraving Marks. SP: Marking Holes. DR: Drilling Holes.
1. Tool Holder.
Fig1. Drawing of tools used in CNC Process and their manufacturing capabilities.
Machine: Haas TM3 Bed Size: 1000 mm x 500 mm. Z travel height: 450mm. Max Spindle Speed: 6,000 rpm. Coolant: Yes Materials: Foam, Timber, Metals Location: Here East.
2: Collet. 3. Head Tool. 4. Tool Diameter. 5.Shank Diameter. 6. Flute Length. 7. Overhang Length.
Fig1. Diagram of setup of CNC Components.
1. CNC Spindle. z Travel
2. Milling Tool. 3.Billet.
x/y Travel (Hass)
4. Sacrificial Material. 5.Machine Bed.
Fig1. Diagram for operation and functionality of CNC.
Machine: Piranha Bed Size: 2500 mm x 1250 mm. Z travel height: 250 mm. Max Spindle Speed: 24,000 rpm. Coolant: No Materials: Foam, Timber. Location: 22 Gordon Street.
Machine: Haas TM1 Bed Size: 700 mm x 300 mm. Z travel height: 450 mm. Max Spindle Speed: 4,000 rpm. Coolant: Yes Materials: Metals. Location: 22 Gordon Street.
Fusion 360
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Models and Drawings
7.5mm
m m 10 Ø
.25 mm
m
m
5 0.
1
Ø
10mm
40mm
Ø
Ø7
m 3m Ø1
.25
m
m 22
m
1
Ø
9mm
6mm
Ø3.3mm
m
m
5 0.
R3m
mm
m
67.5mm
6m
Ø1 0m m R3 mm
77.5mm
Ø1
m
m
m R3
Outside Continuous Fillet 1.5
6m
Chamfer 0.75
Chamfer 0.75
77.5mm
Ø1
Inside Continuous Fillet 1.0
67.5mm
Ø7
10mm
3mm
7.5mm
7mm
4.5mm
1:2 Front View
mm
R10
mm
0 R1
105.6mm
125mm
60mm
115mm
300mm
1:4 Isometric View
Fusion is extremely useful for quick drawings for manufacturing solid objects. Such drawings can be exported directly from the views of fusion and the dimensions are easily obtained from the drawing space and automatically relinked when the model is modified.
Chamfer 0.75 to ease insertion of bearing
Chamfer 0.75 to ease insertion of bearing 1:2 Top View
Fig1. Drawing type of commponent for JEAN PROUVÉ ‘s Brise Soleil profile.
Fusion 360
Modelling process
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Modelling in Fusion 360
Chamfer 0.75 to ease insertion of bearing. H2 and H4 Holes for Metric M6 bolt with standard size socket head to fit flush (RS part no. 281-136). Chamfer 0.75 to ease insertion of bearing. Pocket for plain ball bearing (RS part 618-9957) of size diameter 22mm o/d x 7. Tolerance to achieve a close fit. Hole with metric M4x0.7 6H class right hand thread to accept M4 set screw (RS part no. 052-9949). Inside continuous fillet 1.0 mm. Outside continuous fillet 1.5 mm. H1 and H5 Pocket for IGUS type GFM-0810-05 (RS part no 667-1475) plain linear bearing Tolerance to achieve an interface fit (Push fit by hand).
Modelling in fusion is practical and efficient. The interface allows you to alter your design and by adjusting the parameters the model re-generates automatically based on the new constraints. Fusion is specifically useful for the modelling and design of solid components. However, fusion is not the preferred software for handling complex meshes or free-form structures.
Fig1. Screenshot of Fusion 360 Software interface. Part 3 Fin end-profile.
Fusion 360
Modelling process
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Toolpath simulation
Toolpath: 2D Contour Tool: #1,Endmill diameter 6mm. Toolpath: 2D Pocket Tool: #1,Endmill diameter 6mm. Toolpath: 2D Pocket Tool: #2,Endmill diameter 3mm. Toolpath: 3D Contour Tool: #3,Ball-nose diameter 3 mm. Toolpath: Pencil Tool: #3,Ball-nose diameter 3 mm. Toolpath: 2D Chamfer Tool: #4, Spot-drill diameter 8mm. Toolpath: 3D Horizontal Tool: #1,Endmill diameter 6mm. Toolpath: 2D Contour Tool: #1,Endmill diameter 6mm. Toolpath: 3D Horizontal Tool: #2,Endmill diameter 3mm.
Fusion 360 enables the simulation of the generated toolpaths in its software, in order to facilitate a visual representation of the processes machined on a specific model and stock. Simulation of the toolpaths is very efficient to see the number of step-downs, oversteps and predicts any possible collisions that may occur between the tool and the model or vice during the machining time.
Fig1. Screenshot of Fin end profile in Fusion 360, simulation of toolpath processes.
Fusion 360
Modelling process
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
CNC Milling - Fin end Profile Submission
The submission exercise was useful to reflect upon the many milling processes that can be applied to a specific setup or billet in order to achieve a similar outcome. Thus, it is helpful to have several approaches to the projects and the design of their toolpaths in order to select the option that gives the best quality output of the component is the fastest machining time.
Fig1. Photograph of Milled pieces for Fin end Profile in Haas TM3 machine vice setup. Fig2. Photograph of Milled pieces.
Fusion 360
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
FUSION 360
Timber Milling- Design Project
Milling timber processes can achieve better precision for the assembly of timber structures, with implemented intelligence into the self-aligning joints. Modelling in Fusion 360 and milling in the Haas TM3 machine was eďŹƒcient, even though breakouts in the Timber milling, due to faulty design of the toolpaths can be improved in order to attain better results.
Fig1. Screenshot of Model in Fusion 360, showing milling toolpaths Fig2. Photograph of ďŹ nal product. Milled Timber beam for structure.
Fusion 360
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
3 VIDEOGRAPHY
- 3D modelling interface - Equipment - Storyboard of ямБlm - Final Outcomes
3.
Skills Portfolio
ALFREDO SALGADO FERRER 2018-2019
ADOBE PREMIERE PRO CC Software Interface
Window title : Displays the current model's file name. Workspace: selects the feature to be edited from videos and audios. Menu : Groups Premiere commands by function. Source monitor: Useful for reviewing, and editing videos or audios before importing to the timeline. Program monitor: Reads a preview of the video when imported into the editing timeline and adjusts to a video timeline. Project panel: Contains all the effects provided by adobe premiere, starting from sound effects, transition videos and others. Tools editing: Useful during editing a video. Contains editing tools like the Cut tool, the Selection tool, and others. Timeline editing: For video editing, audio and make additional title effects and others.
Premiere facilitates the edition of media in its native format and allows for the productions of film. The interface is mainly used to adjust poorly exposed or shots with bad lighting or contrast. It is helpful for removing unusual or iterative segments of videos in order to achieve more concise and accurate films. the videos we edit in this software usually portray a workshop process or the design and manufacture development of a project.
Fig1. Screenshot of Premiere Pro Software interface.
Videography
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
ADOBE PHOTOSHOP CC Software Interface
Application Bar: Quick access to various options and functionality. Menu Bar: Access to a wide range of functionality and extra commands. Control Panel: Gives access to settings, without having to wade through menus or panels to find the same thing. Workspace Switcher: Defines the Photoshop workspace template mode. Toolbar: Contains all the tools. Artboard: Defined space for drawing or diagram. Collapsed Panels: Every single panel in Illustrator is listed under the Window. Status Bar: Allows to see the zoom scale.
Photoshop is extremely useful for editing and compositing of photographs and screenshots, 3D artwork and videos. We are encouraged to implement photoshop into our stills and other diagrams in order to make our work clearer and achieve a better quality of documentation.
Fig1. Screenshot of Photoshop CC 2019 Software interface.
Videography
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
ADOBE PREMIERE PRO CC Cameras & Lenses
Camera: Nikon D3100. Lens: F1.8G VR. Camera: Leica Q. Lens: 28mm F1.7 Summilux. Tripod: Befree Advanced Aluminum Travel Tripod lever, ball head.
Videography
Equipment
ALFREDO SALGADO FERRER 2018-2019
VIDEOGRAPHY Story-Board
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OEUF.This short film arose from the aim of documenting the design and manufacturing process of the OEUF project.
OEUF is a collaborative team assignment which undertook the making of a vessel, carried out in the Design for Manufacture programme at The Bartlett faculty of University College London (UCL). The film is divided into twenty scenes. Each one seeks to guide the observer to the understanding of the process that was carried out to generate such a project. The film begins with an introduction to the programme´s name, the project´s name and the University. In the background, there is an inverted scene of a cracked egg. Subsequently, the film situates the observer in the surroundings of UCL and the Here East campus. The third scene captures the aisle of the workshop where the production of the artefact was carried out. The fourth scene continues by demonstrating the conceptualization process of the project and the first sketches. Consecutively, the fifth scene portrays the translation of these sketches into the CAD program. The two-dimensional model is then sent to the laser-cut machine to produce a scale model. The next two scenes capture the laser machine's ignition and the operation of the machine accordingly. Once the model was assembled, a three-dimensional model was generated in which all the elements of the project are combined as shown on the ninth scene. Once the model was generated the production of the real object began. Therefore, the following pictures describe processes such as: the measurement of the material, zooms of the operating band saw, delayed approaches of the lathe machine, the configuration of the structure of the object through the bending of metal and the assembly of it by welding. The last scenes show the tests carried out on the OEUF structure, the adaptation of the three-dimensional digital model to the production measurements and concluding with a rendering shot of the expected final product.
ALFREDO SALGADO FERRER 2018-2019
Camera: Nikon D3100 | Lens: F1.8G VR Camera: Leica Q| Lens: 28mm F1.7 Summilux Edition in Adobe Premiere Pro Soundtrack: https://www.youtube.com/watch?v=f9ZqGFiKwA8
Videography
Story-board of film
ADOBE PHOTOSHOP PRO CC OEUF Stills edition
Fig1. Screenshot of OEUF ďŹ nal Rhino rendered model.
Fig 2. Photograph of OEUF prototype without edition.
Fig 3. Photograph of OEUF prototype edited in Photoshop.
Videography
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
ADOBE PREMIERE PRO CC OEUF “The Making”short film
OEUF is a 1-minute short film edited in Adobe’s Premiere Pro. it is curated from several shots taken inside the workshop and studio spaces of the Design Manufacture campus, Here East. It depicts the design and manufacture process of the design project OEUF carried out in the first term of the programme Vehicle or Vessel. Link:
https://youtu.be/BNjGE8Oo-E8 Videography
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
4 WORKSHOP
- Drawing interface - Processes - Final outcomes
4.
Skills Portfolio
ALFREDO SALGADO FERRER 2018-2019
AUTOCAD
Software Interface Menu Browser: Commands for ďŹ le management, publishing, and utilities. Drawing tabs: Shows all opened drawings. Quick Access Toolbar: New, Open, Save, Print, Undo, and others. Title bar: Displays the product name and the active drawing name. View Cube: Widely used for 3D modelling. Drawing Area: The large area, is where your design happens. Initially, the drawing area shows a grid. Crosshair Cursor: Creates and selects entities you create throughout the design process. (UCS) Icon: Shows the current orientation of x and y vectors of the coordinate system. Layout Tabs: Consists of Model Space and Paper Space layouts. Command Window: shows the selected command.
AutoCAD is mainly used as the default engine for 2D CAD models. Drawings from Rhino can be exported into this interface for their quick edition. Files from this software can be exported as curves in the DFX format required for the Water-jet machine in the workshop. Wireframe drawings can also be exported to illustrator for their quick edition directly from AutoCAD.
Fig1. Screenshot of Auto CAD 2019 Software interface.
Status Bar: Contains numerous quick-access readings, toggle, and selection tools to help you work with the drawing.
Workshop
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
ADOBE ILLUSTRATOR CC Software Interface
Application Bar: Quick access to various options and functionality. Menu Bar: Access to a wide range of functionality and extra commands. Control Panel: Gives access to settings, without having to wade through menus or panels to find the same thing. Workspace Switcher: Defines the Illustrator workspace template mode. Toolbar: Contains all the tools. Artboard: Defined space for drawing or diagram. Collapsed Panels: Every single panel in Illustrator is listed under the Window. Status Bar: Allows to see the zoom scale and the number of artboards.
Illustrator allows for the curation and diagrams made up of vectors and points. This software is helpful in the betterment of diagrams by allowing the control of line-weights and colours. Illustrator is also used in the workshop as the interface that connects with the Trotec laser cutting machine, all files must be imported into illustrator and managed directly before laser cutting.
Fig1. Screenshot of Illustrator CC 2019 Software interface
Workshop
Ideas & Concepts
ALFREDO SALGADO FERRER 2018-2019
STUDIO PROCESSES
Kawai Tsugite - 3D Printing
The studio space enables the use of technology for the combination of 3D modelling and prototyping. The Cura software allows Rhino models to be imported which then can be printed in PLA plastic in the Ultimaker 2.0 printers. This process is incredibly useful, for testing out new prototypes and visualizing physical models.
Fig1. Ultimaker 2.0 3D printing machine, printing grey PLA plastic. Fig2. Finished printing of Japanese joint Kawai Tsuguite (Fixture 1). Fig3. Finished printing of Japanese joint Kawai Tsuguite (Fixture 2). Workshop
Modelling Processes
ALFREDO SALGADO FERRER 2018-2019
WORKSHOP PROCESSES
Milling, Laser cutting and Lathe machine
Milling in the TM3 Haas machine requires several considerations: the use of sacriďŹ cial material as a jig in order to have the same datum point for all the pieces to be milled in the same set up, the clamping locations to avoid collisions and the correct numbering of tools in the coding of the toolpaths in Fusion 360.
Fig1. Final piece on Haas TM3 machine of timber milling. Fig2. Laser cutting of plywood for OEUF scale model prototype of gimbal mechanism. Fig3. Process of lathe induction at BMADE workshop.
Workshop Processes
ALFREDO SALGADO FERRER 2018-2019
WORKSHOP PROCESSES
Welding, Bending & Cutting steel
The Design for Manufacture (DFM) programme encourages the students to get familiar with a large range of machines, machining processes and other techniques inside the workshop space. Some of the examples of the new skills and inductions we undertake are: Metal Inert Gas (MIG) Welding, Tungsten Inert Gas (TIG) Welding, metal bending and metal and timber sawing.
Fig1. MIG Welding of OEUF base frame structure. Fig2. Steel section 40 x 40 mm being bent, to make it into a circular frame structure. Fig3. Cutting of the steel 40 x 40 mm section for OEUF structure.
Workshop
Processes
ALFREDO SALGADO FERRER 2018-2019
WORKSHOP
OEUF - Final mechanisim
The workshop skills and inductions allow us to manufacture previously designed digital models. The ďŹ nal outcome of OEUF intertwined techniques such as: water-jet cutting of 8 mm steel plates, MIG welding of steel plates and square sections of 4 x 4 mm steel, as well as the use of the English wheel and the implementation of bearings for the movement of the gyroscope mechanism of the Design module project.
Fig1. Final mechanism of gyroscope for OEUF project. Fig2. Diagram of Oeuf Components and their assembly.
Workshop
Final Outcomes
ALFREDO SALGADO FERRER 2018-2019
DESIGN FOR MANUFACTURE SKILLS PORTFOLIO 2018 - 2019 ALFREDO SALGADO FERRER BARC0074