SketchBox
RAPID PROTOTYPING INTERFACE THESIS PROJECT BY ANTON ZASYPKIN
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Dessau International Architecture Graduate School Anhalt University of Applied Sciences Š 2014
SketchBOX
rapid prototyping interface
Master Thesis by Anton Zasypkin Studio: Material Perfomance | ss2013/ws2014 1st Advisor: Krassimir Krastev 2nd Advisor: Alexander Kalachev
TABLE OF CONTENT
STUDIO BRIEF THESIS ABSTRACT 3D PRINTING TECHNOLOGY WHAT IS 3D PRINTING? EVOLUTION OF 3D PRINTING TECHNOLOGY SELECTIVE DEPOSITION TECHNIQUES PRINTERS THAT FUSE, BIND GLUE FREE FORM PRINTING 10 PRINCIPLES OF 3D PRINTING 3D PRINTING IN BIG SCALE ARCHITECTURAL APPLICATIONS RESEARCH 3DIA PRINTER PRINCIPLES OF DESIGN ELECTRICAL PARTS: MOTORS, WIRES MOVEMENT SYSTEM DEVELOPMENT: X, Y AXES LIST OF PARTS ELECTRICAL SYSTEM SOFTWARE EXTRUDER PHOTOS MOTION SENSING INPUT DEVICES KINECT KINECT EXPERIMENT LEAP MOTION LEAP MOTION EXPERIMENT ALUMINIUM FOIL BOX ALUMINIUM FOIL BOX EXPERIMENT
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6 8 10 10 12 14 16 18 22 23 24 32 32 35 37 38 45 46 48 49 50 58 60 62 66 68 70 72
TABLE OF CONTENT
OPTIMIZATION STRUCTURE ANALYZE AND PROCESSING BONE STRUCTURE PERSPECTIVES CNC-MILLING CONCLISIONS BIBLIOGRAPHY
76 78 80 82 84 88 90
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MATERIAL PERFORMANCE STUDIO BRIEF
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STUDIO BRIEF
OPEN SOURCE TECHNOLOGY AND ARCHITECTURE The Material Performance group will devote this year’s thesis research to exploring the impact of recent developments in open source software and hardware onto the discourses in contemporary architecture. The fascination with computer-controlled manufacturing has brought the “3D printing phenomenon” to a hype not only amongst architects. From medicine, to the space industry, to fashion, the applications of computer-controlled manufacturing go far beyond the initial expectations, and many claim that the new technology will completely change our lives. While entire 3D printed houses are currently in the process of construction, the technology of large-scale computer-controlled manufacturing is still far from being widely adopted by the construction industry. Only a decade ago it was unthinkable for the average designer or engineer to gain regular access even to smaller scale rapid prototyping technology, as a 3D printer used to cost about 20 K euro or more. But in the last few years, DIY kits developed by academics and hacker communities have brought the price of a 3D printer down to less than 700 Euros, making the equipment extremely accessible, and what is more important - thousands of new applications of the technology are now being explored and developed. The Material Performance Group will acquire as many as possible open source computer-controlled kits and through experimentation develop procedures of design and manufacturing in an attempt to pioneer the full workflow cycle from conception to execution of affordable, high-quality architectural structures developed with open source technology. The industrial revolution completely changed the Earth’s ecology, economy, culture, demography, and yet, for centuries it did not bring up much of an improvement in the living conditions of the average citizen. Only the perfection of the assembly line workflow in the early 20th century granted mass availability of desirable products, decreasing prices and increasing wages, improving the living standards of millions of people, it gave rise to the “middle class” as the back-bone of the 20th century Western society. Furthermore, the availability of mass-produced building constructions and furniture gave rise to the Modernist movement in architecture. One may argue, we are facing a similar milestone in the history of manufacturing at the moment. Until a few years ago, Students who wanted to get educated in the use of CAM technology faced a limited choice of schools and enormous tuition fees to get access to the expensive equipment. Nowadays, one can build a 3D printer at home for about as much as a semester’s tuition fee at DIA, and with free online training learn all the skills needed to use it. Just as open-source software such as Grasshopper and Processing helped to dissipate the skills in complex 3D modelling far beyond the chosen circle of a few corporate institutions, so does the availability of open-source hardware such as Rep-Rap bring manufacturing in the hands of anyone who wishes to get involved in it. The mass availability of both design and manufacturing tools as open source development model is unprecedented in history and will inevitably radically change both the virtual and the material reality around us. Prof. Krassimir Krastev
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SketchBOX THESIS ARSTRACT
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THESIS ABSTRACT
‘’...For me, every day is a new thing. I approach each project with a new insecurity, almost like the first project I ever did. And I get the sweats. I go in and start working, I'm not sure where I'm going. When I can predict or plan it, I don't do it...’’ Frank Gehry SketchBox - the project whose prime objective is to improve, accelerate the process of the architect's work, significantly expand his capabilities. I created a 3D environment for rapid prototyping where the computer can see, sensing the motions, and in the same 3D environment architect has the ability to edit. It gives you the opportunity to create the first sketches, outline without manually entering any input information, unlike the way of traditional 2-dimensional manipulation interaction. In my project, I create a platform for interaction between different technologies. I consider in architecture and in any other fields it is important to follow modern gadgets, tools and to be able to use them, since they are make workflow easier and open up new possibilities. As example highly technical processes such as working with CNC machines brought in the architect's work new perfect device for creating rapid prototypes of computer models. New application of already existing technologies reveals the capabilities of inventions. For example, with using motion sensing technology like Kinect, or Leap Motion and so on let you get a relatively inexpensive device to work with the project in digital 3D environment. Such inventions enabled to computer the "eyes", the ability to see. More traditional input devices, such as mouse or track-pad which generally restrict direct manipulation interaction to a 2D paradigm. As long as you set up and tune all values under what you were imaging in your mind or on paper sketch it will take many manipulations. Data input via 2-dimensional input device takes much time before the desired result is achieved, it is acquired only with experience. 3D motion sensing devices push input data to a new level. Here, without much experience, you can get the desired result by working with the object, model, project as in the work of the sculptor he builds his model according to the movements of the hands. This allows to quickly abandon what seemed right on paper, or to find new ideas for the project. Using CNC machines in this interactive environment greatly increases the efficiency of the process - lets immediately create a physical rapid prototype of the design. A relationship between the "eyes" of the computer and CNC machine technologies open up a new platform for interaction. Workflow get the ability to immediately edit just created 3D digital models and physical prototypes as well at the same time. For example, the use of CNC-milling provide precise process of subtracting the physical model, and by CNC-additive process like 3D printing you can add a new elements to the model with the same precision as well.
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3D PRINTING TECHNOLOGY INTRODUCTION TO THE TECHNOLOGY
3D printing is a process of making a three-dimensional solid object of virtually any shape from a digital model. The term 3D printing is the common term for the correct manufacturing term of “additive manufacturing.� 3D printing is achieved using an additive process, where successive layers of material are laid down in different shapes. 3D printing is also considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as cutting or drilling.
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3D PRINTING TECHNOLOGY
EVOLUTION OF 3D PRINTING TECHNOLOGY SELECTIVE DEPOSITION TECHNIQUES PRINTERS THAT FUSE, BIND GLUE FREE FORM PRINTING 10 PRINCIPLES OF 3D PRINTING 3D PRINTING IN BIG SCALE ARCHITECTURAL APPLICATIONS
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3D PRINTING TECHNOLOGY
EVOLUTION OF 3D PRINTING TECHNOLOGY 1984
2002
The birth of 3d printing Charles Hull, the A working kidney. Aminature functional coufounder of 3D Systems, invents stereolithogra- kidney is produced that is able to filter blood and phy, a printing procces that enables a physical 3D produce diluted urine in an animal. object to be created from digital data. The technology is used to create a 3D model from a picture. 2006 SLS leads to masscustomization in 1992 manufacturing. The SLS (laser sintering machine) Building parts layer by layer. The first becomes viable and opens the door to mass stereo lithographic machine (SLA) is produced by 3D customization and on-demand manufacturing. The Systems. The machine used an UV laser solidiying first machine capable of printing in multiple materiphotopolymer, a viscous liquid to make threedimen- als and densities is created. tional parts layer by layer. 2008 1999 Major breakthrough for prosthetics. The Engineered organs bring new advances first 3D prosthetic leg is produced with all its parts: to medicine. The first lab-grown organ is implanted knee, foot, socket, ect, printed in an unitary complex in humans when young patients undergo urinary structure without assembly. bladder augmentation using a 3D synthehtic scaffold coated with their own cells. 2008 The first selfreplicating printer RepRap 2005 project release Darwin, the first self-replicating Open source collaboating with 3D printer that can print the majority of its own compoprinting. Dr. Adrian Bowyer at university of bath nents. founds RepRap an open source initiative to build a 3D printer that can print most of its own components. 2009 The vision of this project is to democratize DIA kits for 3D printers enter the marketmanufacturing by cheaply distributing RepRap units place MakerBot Industries, an open source to individuals everywhere enabling them to create hardware company for 3D printers, starts sellling DiY products on their own. kits that allow buyers to make their own 3D printers and products.
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2009 From cells to blood vessels A rD bioprinter is used to print the first blood vessel. 2011 First 3D printed robotic aircraft 3D printing allows the plane to be built with elliptical wings, a normally expensice feature that helps improve aerodynamics and minimizes induced drag. 2011 World first 3D printed car Urbee has a comlete 3D printed body and it’s designed to be fuel-efficient and inexpensive. 2012 3D printed prosthetic jaw is implanted. A 3D printer was used to print a customized three dimentional prosthetic lower jaw.
3D PRINTING TECHNOLOGY
IMAGE: HTTP://WWW.GOLOS-AMERIKI.RU/
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3D PRINTING TECHNOLOGY
SELECTIVE DEPOSITION TECHNIQUES FUSED DEPOSITION MODELING (FDM) Fused Deposition Modeling (FDM) is a process where a plastic or wax material is extruded through a nozzle that traces the part's cross sectional geometry layer by layer. The nozzle contains resistive heaters that keep the plastic at a temperature just above its melting point so that it flows easily through the nozzle and forms the layer. The plastic hardens immediately after flowing from the nozzle and bonds to the layer below. The layer thickness and vertical dimensional ranges from 0.013 to 0.005 inches. range of materials are available including ABS, polyamide, polycarbonate, polyethylene, polypropylene, and investment casting wax. + Low cost; + easy to use and assemble = siutable to home use; + wide range of materials; - can not print materials like molten metal or glas.
COUNTUR CRAFTING Contour Crafting it is a fused deposition modeling technque that is mostly used for large scale designs with possible impementation in architecture. It is similar to a desktop printer with the difference that it can use architecture construction materials such as concrete and clay while the printing head can be atached to a robotic arm or a mobile printer for a more flexile reach to the printing area. The advantage is that it represents a cheap alternative to the traditional concrete construction approach in which the concrete is poured in a pre-exiting mold. While it is advantageous for a vertical wall contour construction, it has a deficit in horizontal concrete slab construction which will still require a prior mold. + Time; + no formwork; - size robot comparing to result; - only one material usage; - limitations in extrusion type.
IMAGES: HTTP://WWW.CUSTOMPARTNET.COM/, HTTP://WWW.OFFGRIDWORLD.COM/
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3D PRINTING TECHNOLOGY
LAMINATED OBJECT MANUFACTURING (LOM) Laminated Object Manufacturing (LOM): process that creates models from inexpensive, solid- sheet materials. It is similar to stereolithography in that it slices a three-dimensional electronic file from the computer to the LOM machine to produce parts for visualization models, casting patterns, and designs. The main components of the system are a heated roller to apply pressure to bond the sheet to the layer below, and a laser to cut the outline of the part in each sheet layer. Parts are produced by stacking, bonding, and cutting layers of adhesive-coated sheet material on top of the previous one. A laser cuts the outline of the part into each layer. The platform then rises slightly and the heated roller applies pressure to bond the new layer. The laser cuts the outline and the process is repeated until the part is completed. After a layer is cut, the extra material remains in place to support the part during build.
LASER ENGINEERED NET SHAPING (LENS) It was the first technique among the 3D printers to use metal. It can be spray a metal powder onto a base substrate. Some of the powder onto a base substarate. Some of the power will slide over but some will be fused by a laser when it reaches the focal point of the laser, thus forming successive additions to base metal. Multiple nozzles can be used to spray different metals such as titanium and stainless steel thus forming an alloy type of metal that is hard and durable. It can consider as well the ratio of each metal by spraying from different angels thus creating a graded metal. It is most used in areospace and automotive indusry.
IMAGES: HTTP://WWW.CUSTOMPARTNET.COM/, HTTP://WWW.RPM-INNOVATIONS.COM/
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3D PRINTING TECHNOLOGY
PRINTERS THAT FUSE BIND GLUE STEREOLITHOGRAPHY (SL) Stereolithography (SL): A layer manufacturing technology in which the layers are formed by using a laser to solidyfie layers of photo-sensitive polymer in the desired shape. It uses a low-power, highly focused UV laser to trace out successive cross-sections of a three-dimensional object in a vat of liquid photosensitive polymer. As the laser traces the layer, the polymer solidifies and the excess areas are left as liquid. When a layer is completed, a leveling blade is moved across the surface to smooth it before depositing the next layer. Once complete, the part is elevated above the vat and drained. Excess polymer is swabbed or rinsed away from the surfaces. In many cases, a final cure is given by placing the part in a UV oven. After the final cure, supports are cut off the part and surfaces are polished, sanded or otherwise finished.
POWDER BED AND INKJET HEAD 3D PRINTING THREE DIMENTIONAL PRINTING (3DP) The additive fabrication technique of inkjet printing is based on the 2D printer technique of using a jet to deposit tiny drops of ink onto paper. In the additive process, begins with the build material (thermoplastic) and support material (wax) being held in a melted state inside two heated reservoirs. These materials are each fed to an inkjet print head which moves in the X-Y plane and shoots tiny droplets to the required locations to form one layer of the part. Both the build material and support material instantly cool and solidify. After a layer has been completed, a milling head moves across the layer to smooth the surface. The elevator then lowers the build platform and part so that the next layer can be built. After this process the part can be removed and the wax support material can be melted away. + Eccellent accuracy and surface finishes; + include jewelry, medical devices, and high-precisions products; -slow speed (two nozzles, multi nozzels); -few material options; -fragile parts.
IMAGES: HTTP://WWW.CUSTOMPARTNET.COM/
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3D PRINTING TECHNOLOGY
LASER SINTERING (LS) Selective Laser Sintering (SLS): a flexible technology that uses a CO2 laser beam to fuse (sinter) layers of nylon, metal, or trueform powdered materials into a three-dimensional model. It is a leading rapid prototyping technology, providing more choices of materials for flexibility, and more applications than other technologies. SLS uses a moving laser beam to trace and selectively sinter powdered polymer and/or metal composite materials into successive cross-sections of a three-dimensional part. The parts are built upon a platform that adjusts in height equal to the thickness of the layer being built. Additional powder is deposited on top of each solidified layer and sintered. This powder is rolled onto the platform from a bin before building the layer. The powder is maintained at an elevated temperature so that it fuses easily upon exposure to the laser. + Wide range of materials, including nylon, glass-filled nylon, SOMOS (rubber-like); + special support structures are not required because the excess powder in each layer acts as a support to the part being build.
TWO - PHOTON LITOGRAPHY 3D LASER LITHOGRAPHY / DIRECT LASER WRITING It was based on a multiphoton abs-orption process of a material whose transparency is at the same wavelength as the laser beam. It works with multiple pulses at high energies. The molecules contained in the resin material are activated by the laser beam and induce a chain reaction in other components of the resin, called monomers which are then turned into a solid. In this process the activation occurs only when two photons of the laser baem are absorbed at once. A big difference from the standard 3D printing technology where a layer is created on top of the previous one is that the solidifcation can occur in any place of the liquid resin at the focal point of the laser. It is most suitable for creating nanscale 3D printed structures.
IMAGES: HTTP://WWW.CUSTOMPARTNET.COM/, HTTP://WWW.NANOSCRIBE.DE/
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3D PRINTING TECHNOLOGY
FREE FORM PRINTING SUSPENDED DEPOSITIONS
ANTI GRAVITY OBJECT MODELING
Technology is based on injecting and suspending light-curing resin in a gelatinous medium, one is afforded the ability to shape freeform objects without the need for molds or other subtractive manufacturing processes that would otherwise be necessary. The gel acts as an omnidirectional support material which is reusable, so there is no wasted material. One major distinction between this project and other rapid prototyping processes is the ability to utilize 3D vector-based toolpaths. Virtually all other processes use paths generated via contouring a digital model, and rely on the hardening of each successive layer before being able to move on to the next. The suspension of resin in space without added support material allows for the ability to navigate and fabricate directly on and around other existing objects within the Gel, as well as the ability to observe the process from any angle. The suspension of time in this process allows for tool changes, manual injections, on-the-fly robotic injections, multi-material injections, live modification of the digital or physical model, and the ability to physically "undo" (resin removal via suction or scooping).
A brand new method of additive manufacturing. This patent-pending method allows for creating 3D objects on any given working surface independently of its inclination and smoothness, and without a need of additional support structures. Conventional methods of additive manufacturing have been affected both by gravity and printing environment: creation of 3D objects on irregular, or non-horizontal surfaces has so far been treated as impossible. By using innovative extrusion technology it is possible to neutralize the effect of gravity during the course of the printing process. This method gives a flexibility to create truly natural objects by making 3D curves instead of 2D layers. Unlike 2D layers that are ignorant to the structure of the object, the 3D curves can follow exact stress lines of a custom shape. Finally, new out of the box printing method can help manufacture structures of almost any size and shape.
www.nstrmnt.com/#/suspended-depositions/
IMAGES: HTTP://DESIGNPLAYGROUNDS.COM/, HTTP://BETA.HSTOR.ORG/
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www.mataerial.com
3D PRINTING TECHNOLOGY
CUSTOM MULTI FIBER EXTRUSION
STONE SPRAY
This technology os based on the silk formation process in a silk worm cocoon. In an experiment a computer tracked the movements of a silk worm while constructing its cocoon and translated data to a printer atached to robotic arm. The data will be used to construct a pavilion with the dimensions of 366 by 366 cm. The arm will deposit silk fibers and a gluey “matrix”. The matrix will most probably be made of a new type of material called shrik which is made of discarded form silk. Shrilk is a thin and transparent material, flexible and strong as aluminum and yet, it has half the weight and it is biodegradable.
Stone Spray is a robotic 3D printer that produces architecture out of soil.The mechanised device collects dirt/sand on site and then sprays it from a nozzle in combination with a binder component. When this mixture hits the surface it solidifies to create sculptural forms. Because the movements of the robot are digitally controlled by computer, the designer has direct input on the resulting shape. Unlike other 3D printers, the Stone Spray robot can print multi-directionally, even on vertical surfaces. The Stone Spray robot sprays the grains of sand or soil out of one nozzle and glue out of another to make a mixture that solidifies as it hits a surface .Unlike other 3D printers, the robot's arm moves multi-directionally and can also print onto vertical surfaces. Stone Spray is a research project by Anna Kulik, Inder Shergill and Petr Novikov, under the supervision of Marta Malé-Alemany, Jordi Portell and Miquel Lloveras of IAAC. www.stonespray.com
IMAGES: HTTP://STATIC.DEZEEN.COM/, HTTP://WWW.SOLIDSMACK.COM/
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3D PRINTING TECHNOLOGY
FREE FORM PRINTING SOLAR SINTERING
D-SHAPE
This was a solar-powered, semi-automated low-tech laser cutter, that used the power of the sun to drive it and directly harnessed its rays through a glass ball lens to ‘laser’ cut 2D components using a cam-guided system. The Sun-Cutter produced components in thin plywood with an aesthetic quality that was a curious hybrid of machine-made and “nature craft” due to the crudeness of its mechanism and cutting beam optics, alongside variations in solar intensity due to weather fluctuations. Silicia sand when heated to melting point and allowed to cool solidifies as glass. This process of converting a powdery substance via a heating process into a solid form is known as sintering and has in recent years become a central process in design prototyping known as 3D printing or SLS. These 3D printers use powdered plastics, resins and metals. By using the sun’s rays instead of a laser and sand instead of resins, I had the basis of an entirely new solar-powered machine and production process for making glass objects that taps into the abundant supplies of sun and sand to be found in the deserts of the world. - size of robot comparing to result; + nature alike structures; + architectural scale products.
D-Shape appears like a big aluminium structure inside of which the building will be constructed. This structure holds the printer head, which of course is the real core of the new technology. Despite its large size, the structure is a very light and it can be easily transported, assembled and dismantled in a few hours by two workmen. The Computer design obtained is downloaded into a STL file and is imported into the Computer program that controls D-Shape’s printer head. The process takes place in a non-stop work session, starting from the foundation level and ending on the top of the roof, including stairs, external and internal partition walls, concave and convex surfaces, bas-reliefs, columns, statues, wiring, cabling and piping cavities. During the printing of each section a ‘structural ink’ is deposited by the printer’s nozzles on the sand. The solidification process takes 24 hours to complete. The printing starts from the bottom of the construction and rises up in sections of 5-10mm. Upon contact the solidification process starts and a new layer is added. - size of robot comparing to result; + nature alike structures; + architectural scale products.
www.markuskayser.com
www.d-shape.com
IMAGES: HTTP://WWW.CREATIVEAPPLICATIONS.NET/, HTTP://SURVINCITY.COM/
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3D PRINTING TECHNOLOGY
IMAGE: HTTPS://PLUS.GOOGLE.COM/
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3D PRINTING TECHNOLOGY
10 PRINCIPLES OF 3D PRINTING 1. Manufacturing complexity is free. Printing a complex design is no more expensive than printing a simple design. 2. Variety is free. A 3D printer only requires a new digital blueprint and raw materials to create an infinite variety of forms. 3. No assembly required. Traditional manufacturing requires assembling many parts, however, 3D printing can print fully assembled final products, reducing labor, global supply chains, and freight costs. 4. Zero lead time. Products can be printed on demand, eliminating inventory. 5. Unlimited design space. 3D printers can print shapes never before possible with traditional manufacturing methods. 6. Zero skill manufacturing. A 3D printer requires less operator skill than traditional manufacturing methods. 7. Compact, portable manufacturing. 3D printers have recently become small enough for home or office use, even as small as microwave ovens. 8. Less waste by-product. Depending on the materials involved, 3D printing can significantly reduce waste from traditional machining methods. 9. Infinite shades of materials. Blending and mixing different kinds of raw materials into a product will become possible in new ways with 3D printing. 10. Precise physical replication. Digital 3D modeling allows unlimited copying of designs without loss of fidelity. Similarly, the 3D model-file is not degraded, regardless of how many times the object is printed.
“Fabricated: The new world of 3D printing� by Hod Lipson and Melba Kurman.
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3D PRINTING TECHNOLOGY
3D PRINTING IN BIG SCALE APPLAYING 3D PRINTER TECHNOLOGY TO THE BIG SCALE Why would printing be a better way to construct such a large structure instead of using existing technologies? How 3D printing be implemented in a reasonable way for architectural purposes? What material can be used at the present time? The current building construction sector has its lomitations as regards to its ability to create customized geometries. 3d printing can easly link digital world with physical one with realitvely low cost and time consuption allowning to create complex geometries. PROBLEMS: - small size of objects 90 % of the volume of printers body; - the printer body is a fixed element and having to be transported on site, to create a building smaller than itself, especially in low access locations, might create some problems; - the printer must be stiff enought to sustain it’s own weight, resist wind forces and jkeeping the required precision while printing; - the difficulty to use the type of printers that fuse or bind materials from an existing container containing material will be direct depedent on the printer size. The larger the container, the larger the mass and pressure of material it has to sustain; - if the selective deposition printers are more pragmatic than the fusing ones in ti=his sense, they do not benefit of the same freedom as the previous ones in terms of shaper optimization, which means it would be nearly impossible to print in a selective deposition technique an horizontal surface as a slab for example.
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3D PRINTING TECHNOLOGY
ARCHITECTURAL APPLICATIONS CONTEMPORARY PROJECTS
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3D PRINTING TECHNOLOGY
FABCLAY ANIGRAVITY SYSTEM LANDSCAPE HOUSE SOFTKILL DESIGN DUS ARCHITECTS WINSUN DECORATION DESIGN ENGINEERING CO.
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3D PRINTING TECHNOLOGY
FABCLAY FabClay is project done by Saša Jokić (Serbia), Starsk Lara (Colombia) and Nasim Fashami (Iran) ,based on the idea of robotic additive manufacturing fabrication, innovative materials and computational tools. The research is being conducted at the Institute for Advanced Architecture of Catalonia (IAAC) in Barcelona at Digital Tectonics course lead by Marta Male Alemany with assistance of Jordi Portell and Miquel Lloveras.
IMAGES: HTTP://WWW.FABCLAY.COM/
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3D PRINTING TECHNOLOGY
MATAERIAL - ANTIGRAVITY SYSTEM Is a brand new method of additive manufacturing. This patent-pending method allows for creating 3D objects on any given working surface independently of its inclination and smoothness, and without a need of additional support structures. Conventional methods of additive manufacturing have been affected both by gravity and printing environment: creation of 3D objects on irregular, or non-horizontal surfaces has so far been treated as impossible . By using innovative extrusion technology we are now able to neutralize the effect of gravity during the course of the printing process. This method gives us a flexibility to create truly natural objects by making 3D curves instead of 2D layers. Unlike 2D layers that are ignorant to the structure of the object, the 3D curves can follow exact stress lines of a custom shape. Finally, our new out of the box printing method can help manufacture structures of almost any size and shape.
IMAGES: HTTP://WWW.MATAERIAL.COM/
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3D PRINTING TECHNOLOGY
JANJAAP RUIJSSENAARS - 3D PRINTED HOUSE The Landscape House will be printed in sections using the giant D-Shape printer, which can produce sections of up to 6 x 9 metres using a mixture of sand and a binding agent. Architect Janjaap Ruijssenaars of Universe Architecture will collaborate with Italian inventor Enrico Dini, who developed the D-Shape printer, to build the house, which has a looping form based on a Mรถbius strip.The team are working with mathematician and artist Rinus Roelofs to develop the house, which they estimate will take around 18 months to complete. The D-Shape printer will create hollow volumes that will be filled with fibre-reinforced concrete to give it strength. The volumes will then be joined together to create the house.
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3D PRINTING TECHNOLOGY
SOFTKILL DESIGN - PROTOHOUSE 2.0 London architecture team Softkill Design has designed a conceptual house that would be 3D printed in sections in a factory and fitted together on site. Designed to cantilever out from a hillside, the structure of the house was generated using an algorithm that imitates bone growth to deposit material where it is needed along lines of stress, resulting in a fibrous web rather than a solid envelope. The house would be printed in 31 sections using the largest 3D printer currently available, then transported by truck to the site and fitted together.
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3D PRINTING TECHNOLOGY
JANJAAP RUIJSSENAARS - 3D PRINTED CANAL HOUSE While Duch architect Janjaap Ruijssenaars from Universe Architecture in Amsterdam plans to print a one-piece “endless” building lastest in year 2014 and Softkill Design, a London based desing collective is working on a second version of the 3D printed Protohouse, antoher Dutch studio, DUS Architects, is planning to build the first 3D printed canal house in Amsterdam. It will be 3D printed entirely. DUS Architects will work with KamerMarker, the world’s first largescale movable 3D printer. The desing of each building component will be first 3D printed in small scale 1:20. When the design will be optimal, the Kamer Maker will print out each room in one piece.
IMAGES: HTTP://WWW.EOHOUSE.NET/, WWW.TECMANIA.CH/
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WINSUN NEW MATERIALS - CONCRETE 3D PRINTED HOUSES The WinSun Decoration Design Engineering Co. has printed 10 homes in 24 hours out of recycled materials. The Chinese houses, on the other hand, weren't built onsite. They were printed in pieces and then put together in Shanghai's Qingpu district. The pieces are made using recycled construction materials and industrial waste to form a concrete aggregate, Gizmodo reports. The 3-D printer used to build the houses is 500 feet long, 33 feet wide and 20 feet high. Each home costs around $4,800 to build. Using this technology means that construction workers can be saved from exposure to hazardous or dusty working environments, Yihe added. Thus far, quality checks for printed buildings are undertaken on a piece-by-piece basis, as there are no building codes for them and 3D printed houses are not legislated for under Chinese law. While the current batch of houses are standalone, one-storey structures, the company hopes its technology will eventually be used to make skyscrapers.
3D PRINTING TECHNOLOGY
CALIFORNIA STUDIO SMITH|ALLEN HAS COMPLETED THE WORLD'S FIRST ARCHITECTURAL STRUCTURE USING STANDARD 3D PRINTERS, IMAGE: HTTP://4.BP.BLOGSPOT.COM/
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RESEARCH
3DIA PRINTER
DESIGN, DEVELOPMENT DESCRIPTION
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RESEARCH - 3DIA PRINTER
PRINCIPLES OF DESIGN ELECTRICAL PARTS: MOTORS, WIRES MOVEMENT SYSTEM DEVELOPMENT: X, Y AXES LIST OF PARTS ELECTRICAL SYSTEM SOFTWARE EXTRUDER PHOTOS
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RESEARCH - 3DIA PRINTER
PERSPECTIVE VIEW
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RESEARCH - 3DIA PRINTER
PRINCIPLES OF DESIGN After theoretical reseach, we decided explore this 3D printing technology and it’s limitations from a practial point of view by building a 3D printer. The main objectives of the design were big size and possibility of adapting the machine to other purpooses besides 3D printing. The following chapter will provide information on each major part of the 3D printer system and the different problems that we faced during the construction process: 1/ FRAME 2/ MOVEMENT SYSTEM In order to allow the machine to move in three axes, we need: X-axis (moves left-to-right), Y-axis (moves front-to-back), Z-axis (moves up-and-down). We tested three diffrent types of movement system for Y and X axes: gear, belt and rod. First two occurde to be a failure because of big spam of the printer. Big size of machine regarding its big spans and its weight, was the reason of a lot of problems. For Z axis we chose rod system as well. Such mechanism allows lift up and down pretty heavy central part (X axis) with big precision and fixation of position. 3/ ELECTRICAL SYSTEM: _electrical control; _circuit; _wiring. 4/ EXTRUDER 5/ SOFTWARE: _Arduino; _Pronterface; _Slicer.
FRAME
Z AXIS MOVEMENT SYSTEM
X, Y AXES MOVEMENT SYSTEM
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3D SECTION
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ELECTRICAL PARTS: MOTORS, WIRES MOTORS All axes are driven by NEMA 17 motors. Axes Y and X have one motor each, Z axis needs two motors which works simultaneously. WIRES First, to avoid overheating of electrical system we decided to change all thin wires that came originaly with most parts to thick ones. After few attemps of simply weld wire connections we decided to use adaptors. That allow us to avoid problems coused with slight shaking of thick wires during the machine is running. This shaking changes voltage and breaks connections in sensitive electrical circuit.
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MOVEMENT SYSTEM DEVELOPMENT: X, Y AXES
GEAR SYSTEM
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GEAR SYSTEM First system. It was build from laser cutted parts: _gears; _linear gears; _supporting parts. In general, the system itself worked well, except not allowed to achieve enough precision. Main problem we faced with wooden gear system was backlash. Even when all system was laser cutted there are small difference between CAD model and real part. It appears due thickness of laser itself and gear’s tooths wear. Another obstacle - the restriction in max size of the parts in laser cut machine we used. That’s why in addition we had to design connection nodes in our gear system design. Decreasing the integrity of the system we thus decreased its structural strength quality. CONCLUSIONS: + length easy to expand; + variety of design according to needs; - backlash, hence low precision; - parts wear; - needs supporting parts.
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MOVEMENT SYSTEM development: X, Y AXES
BELT SYSTEM
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BELT SYSTEM Second system. Requires following parts: _belts; _pulleys; _connections to motors. The most popular system for small 3d printers. Initially we tried to avoid such system for several reasons, including due to the assumption that the unusual size of our 3d printer and hence unusual length of the belt would require much more powerful motors. Belt system was working with problems. Intermittent movement, as we assumed, was caused by not enought poweful motors, not enought precise handmade connections to motors. However big span did not allowed to achieve right tension on the belts. CONCLUSIONS: + light weight; + small size; + good for small 3d printers; - require precise installation; - require more powerful motors; - expensive.
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MOVEMENT SYSTEM DEVELOPMENT: X, Y AXES
ROD SYSTEM
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ROD SYSTEM Third one an the most suscessful system. Needs: _hex nuts; _threaded rod; _ball bearings. The best result we got with this system. Beign strong enough not to be curved by the long span and beign incredibly accurate at the time of controlling it with the software. Before archieve that good result we had to improve a bit motor and bearing holder part. Since motor connectors out of hex nuts were handmade, tolerance and accuracy were not 100% perfect. That’s why we got problem with slightly shifting in axis of rotation and hence shaking. To avoid this we made cuts in MDF holder parts around the motors and bearings. After that all imperfections and shaking were damped down. CONCLUSIONS: + uniformly distributed load on the motor; + lenght of rod doesn’t depend on the power of the motor; + inexpensive compare to over tested systems; +good for any size of 3d printer; + good precision; - needs high accuracy in motor connectors fabrication.
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ELEVATIONS
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LIST OF PARTS MECHANICS: _threaded rod M16 (x4); _hex nuts M16 (x12); _hex nuts M16 long (x2); _linear reil (x4); _round rod 8 mm (x4); _bearing LM-8-UU-AJ (x4); _ball bearing 16 (x4).
TOP VIEW
ELECTRONICS: _stepper motor NEMA 17 (x5); _power supply 12V (x1); _Arduino Mega 2560 R3 (x1); _RAMPS 1.4 (x1); _Pololu A4988 controler (x4); _end stop (x3); _PCB heatbed MK2a (x1); _extruder WADE 0.4 (x1); _wire 1.5 (up to 20 m). X AXIS PLAN VIEW
FRAME: _MDF 12 mm (); _MDF 3 mm (); _wooden squared beam 25x25 mm (16 m); _bolt (); _nut (); _washer (); _screw ().
Y AXIS PLAN VIEW
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ELECTRICAL SYSTEM - CIRCUIT
extruder motor
heated bed thermistor x endstop y endstop z endstop Z motor
hot end thermistor hot end power
heatd bed power main power supply
X motor
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Y motor
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ELECTRICAL SYSTEM - MICROCONTROLLERS ARDUINO MEGA 2560 Components on the board interface between the microcontroller and your computer so that your computer can upload firmware directly through a USB cable.
RAMPS 1.4: _process G - code instructions; _control the four steeper motor controllers; _control the temperature of the hot-end and monitor the hot-end thermistor; _passing sigmal from end stops; _control the temperature of the heated bed and monitor the heated bed termistor.
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SOFTWARE DIGITAL PROCESS AND FABRICATION PRINCIPLE THROUGH COMPUTER SOFTWARES FIRMWARE AND G-CODE Reprap electronics are controlled by an inexpensive CPU such as the Atmel AVR processor. Atmel processors are what Ardui1 no based microcontrollers use. In Arduino we have loaded ,G-codes called Sprinter, wich controles 3d printers. GEOMETRY GENERATION SOFTWARE CAD tools in the truest sense are designed to allow you to 2 easily change and manipulate parts based on parameters. Sometimes CAD files are referred to as parametric files. SLICING SOFTWARE Slic3r is the tool you need to convert a digital 3D model into printing instructions for your 3D printer. It cuts the model into 3 horizontal slices (layers), generates toolpaths to fill them and calculates the amount of material to be extruded. G-CODE SENDER Printrun is a set of G-code sending applications, written by Kliment. It consists of printcore (dumb G-code sender), pronsole 4 (featured command line G-code sender), pronterface (featured G-code sender with graphical user interface), and a small collection of helpful scripts.
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EXTRUDER WADE EXTRUDER The extruder consists of two parts: a cold part that feeds the plastic filament (ABS) and a hot bottom part that melts and extrudes the plastic. The extruder is also controlled by Stepper Motors. The nozzle is the most important part of the hot-end. The nozzle is the end of the heater barrel where the melted plastic is extruded.
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PHOTOS
3DIA PRINTER OVERVIEW
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ELECTRONICS: MICROCONTROLLER, RAMPS, POWER SUPPLY
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PHOTOS
NEMA 17 MOTOR FOR Z AXIS
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ROD SYSTEM FOR X AXIS, MOTOR CONNECTOR
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PHOTOS
OLD BELT SYSTEM FOR Y AXIS
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OLD BELT SYSTEM FOR Y AXIS
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PHOTOS
OLD BELT SYSTEM FOR Y AXIS, PLATE WITH WADE EXTRUDER
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WADE EXTRUDER
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RESEARCH
MOTION SENSING INPUT DEVICES INTRODUCTION, APPLICATION OF TECHNOLOGY
Motion sensing technologies allows to track changing the position of an object in space relative to the sensor itself or its surroundings. This technology was first applied as a photogrammetric analysis tool in biomechanics research in the 1970s and 1980s, and nowdays expanded in many fields. Motion sensing technologies offers rapid, real-time data input.
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KINECT LEAP MOTION ALUMINIUM FOIL BOX
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KINECT
IMAGE: HTTPS://WWW.KINECT.COM/
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KINECT Kinect is that it unlocked areas of computer interaction that were previously only accessible to researchers with labs full of expensive experimental equipment. At the same time Kinect was built for skeleton tracking, not for 3D scanning. As a 3D scanner, it has problems with noise, holes, accuracy, and scale. And in the best case, a depth image is still just a single surface. Kinect is more suitable for whole-body tracking in a space the size of a living room. It can recognize parts of the bodyright up to facial expression of user. This allow to assign each of them any individual command. In my project SkretchBOX I only use the right and left hands. In addition, it is important to note that using Kinekt you can shoot 3D scan of space or objects. Thus, we can work on a 1:1 scale directly. Conclusions: + enough presicion for bigger scale; + big open source base; + room scale projects affordable; - bad presicion for finger’s tracking.
INCREAE SIZE OF MESH BRUSH
ADDING MESH BRUSH
KINECT GASTURE CONTROLL SYSTEM
SUBTRACTING MESH
LEAP MOTION GASTURE CONTROLL SYSTEM
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KINECT TEST_1
KINECT TEST_2
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LEAP MOTION
IMAGE: HTTPS://WWW.LEAPMOTION.COM/
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LEAP MOTION BODY
Leap Motion is a computer hardware sensor device that supports hand and finger motions as input, analogous to a mouse, but requiring no hand contact or touching. Using two monochromatic IR cameras and three infrared LEDs, the device observes a roughly hemispherical area. The LEDs generate a 3D pattern of dots of IR light and the cameras generate almost 300 frames per second of reflected data, which is then sent through a USB cable to the host computer, where it is analyzed by the Leap Motion controller software using "complex math" in a way that has not been disclosed by the company, in some way synthesizing 3D position data by comparing the 2D frames generated by the two cameras. The smaller observation area and higher resolution of the device differentiates the product from the Kinect, which is more suitable for whole-body tracking in a space the size of a living room. In a demonstration to CNET, The Leap was shown to perform tasks such as navigating a website, using pinch-to-zoom gestures on maps, high-precision drawing, and manipulating complex 3D data visualizations. In terms of my thesis I explore possibilities if this device, its limits and how it could be applayed to aims of my project.
IMPLEMENTATION OF LEAP MOTION AS TOUCHLESS SCREEN
60 cm 8 cm 50 cm 70 cm 35 cm 8 cm 15 dig
CONCLUSIONS: + very high presicion; - small area of interaction. Swipe gesture
IMAGE: HTTPS://WWW.LEAPMOTION.COM/
LEAP MOTION OPERATING RANGE
Circle gesture
Screen tap gesture
Key tap gesture
LEAP MOTION GASTURE CONTROLL SYSTEM
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LEAP MOTION TEST The first limitation of Leap Motion sensor - is the size of operating area. For aims of my thesis project I had to increase this zone. The most presice area of interaction was tested. It represents an elongate rectangle volume with bounders 35 cm high, 60 cm wide and 8 cm depth. To increase spatial freedom of interaction I need to extend Leap Motion operating range. With usage of open source software like Processing allows me to script rules for it. 2-dimentional
(0,0)
(10,0)
(0,0,0)
(10,0,0)
Y EXTENDED LEAP MOTION OPERATING RANGE
3-dimentional -z (0,0,-10)
(10,0) +x
Y
+x
In this test its obvious that adding depgh function in script significant extend interaction area. Combination of open source software and hardware we able to improve devices in the way we need it. Thus we use 100% of invention potencial possibilities.
(0,10,0)
+y
+y
PROCESSING COOIRDINATION SYSTEM
SCRIPT In Processing to each finger added mesh brush function. By moving hand we got 3D mesh out of each finger. To increase depth bound in case of Processsing it means to change Z-value varible. For this purpose I choose mouse Y value accordingly to Processing 2D system. If we need to move operating range deeper, we move mouse up, if go back - other way round. With this extension we got much bigger zone for interaction with the same high precision.
IMAGE: HTTPS://WWW.LEAPMOTION.COM/
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EXTENDED LEAP MOTION OPERATING RANGE TEST
RESEARCH - MOTION SENSING INPUT DEVICES
EXTENDED LEAP MOTION OPERATING RANGE TEST
EXPENSION OF LEAP MOTION LIMITS RESULT
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ALUMINIUM FOIL BOX
3D MOTION CONTROL SYSTEM THROUGH ALUMINIUM FOIL BOX
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RESEARCH - MOTION SENSING INPUT DEVICES
ALUMINIUM FOIL BOX SYSTEM In study of motion sensing technology was made handmade device, which allows to track the movement of the hand in space inside the box. The space inside the cube is a 3-dimensional electric field, where each side of cube works as one axis: X, Y and Z. The signals of hand position relative to each of the sides translates the 3d location of user's hand. Cube made of 3 MDF plates, each of its side is glued with aluminum foil. Foil pieces not touching each other so as not to influence to the electrical circuit and not upset signals of hand manipulations. Each side connected with shielded wires. In the circuit resistors are used to reduce the so-called noise and improve the accuracy of the signals. Electric circuit runs through the Arduino Uno microcontroller, which initially takes the variable values of hand location and accordingly the force of user's electrical field interaction with the electric field within box. Then those values transforms into the data stream. After that data transmitted further to the processing. Thus with the help of open source software and hardware we get handmade 3D motion sensor. This device also can work with rapid prototyping technologies. The same as in the case of the Kinect and Leap Motion, I wrote script to operate the device in Processing according to the objectives of my project. Process: _detect location of user’s hand; _pressing "A" - adding mesh to model; _press "B" - subtracting model; _press "S" - save model; _press from "1" to "9" - change the size of brush.
ELECTRIC FIELD IN ALUMINIUM FOIL PLATE CONNECTED TO ARDUINO
USER'S HAND ACTS AS THE GROUNDED PLATE AND CLOSING THE CIRCUIT
CONCLUSION: + cheap parts, sensor could be done by hand; + size of interaction area could be adapted as needed; - needs higher precision. LOCATION OF THE RED BALL IN 3D SPACE CONTROLED BY USER’S HAND
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ALUMINIUM FOIL BOX TEST
MODELING WITH ALUMINUIM FOIL BOX
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MODEL STRUCTURE OPTIMIZATION
ALUMINIUM FOIL BOX TEST RESULT
ALUMINIUM FOIL BOX TEST RESULT
ALUMINIUM FOIL BOX TEST RESULT AFTER STRUCTURE OPTIMIZATION
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BOX: _MDF 3 mm 25x25 cm (x3); _aluminium foil 24x24 cm (x3).
ELECTRICAL PARTS
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ELECTRICAL SYSTEM: _Arduino Uno R3 (x1); _shielded wire with alligator clips 50 cm (x3); _280k resistor (x3); _10k resistor (x3); _wire 0.7 (up to 40 cm).
Frequency (pitch)
RESEARCH - MOTION SENSING INPUT DEVICES
THEREMIN EFFECT BASED Termenvox is an early electronic musical instrument controlled without physical contact by the thereminist (performer). It is named after the name of its Russian inventor, Leon Theremin, who patented the device in 1928. The musician stands in front of the instrument and moves their hands in the proximity of two metal antennas. The distance from one antenna determines frequency (pitch), and the distance from the other controls amplitude (volume). The performer's hand acts as the grounded plate (the performer's body being the connection to ground) of a variable capacitor in an L-C (inductance-capacitance) circuit, which is part of the oscillator and determines its frequency. The difference between the frequencies of the two oscillators at each moment allows the creation of a difference tone in the audio frequency range, resulting in audio signals that are amplified and sent to a loudspeaker. This principle scheme later is an foundation for “Tic Tac Toe� by Kyle McDonald.
Amplitude (volume)
THEREMINVOX PRINCIPLE SCHEME
IMAGE, SCHEME: HTTP://WWW.THEREMLN.RU
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OPTIMIZATION
3D MODEL POSTPROCESSING
Structural optimization is the subject of making an assemblage of materials sustain loads in the best way. It is a mathematical approach that optimises material layout within a given design space for a given set of loads and boundary conditions. This optimization process takes in consider to analyze model before printing.
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3D PRINTING TECHNOLOGY
STRUCTURE ANALYZE AND PROCESSING BONE STRUCTURE
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STRUCTURE ANALYZE AND PROCESSING BONE STRUCTURE Bone is a tissue with a complex 3-dimensional structure, consisting of struts and plates, which attains its mature morphology during growth in a process called ‘modeling’. In maturity, the tissue is renewed continuously by local bone resorption and subsequent formation in a process called ‘remodeling’. Both these metabolic activities are executed by bone-resorbing osteoclastic and bone-forming osteoblastic cells. It is known that bone mass and trabecular orientation are adapted to the external forces and that alternative loading conditions lead to adaptations of the internal tissue architecture. It is capable of optimizing its internal tissue structure under the influence of external forces to fulfill its primary function, mechanical load transfer. This paradigm was originally known as Wolff’s Law (1892). How the bone actually produces its internal architecture to fulfill its task in an optimized sense is currently unknown, but it is obvious that mechanical feedback must be involved. In this paper its taken under cinsider the application of computer simulation to investigate the remarkable adaptive processes. Initially, theories for bone adaptation related bone density changes directly to mechanical, strain derived variables as effects of external forces. Cellular biological materials have intricate interior structures, self-organised in hierarchies to produce modularity, redundancy and differentiation. As Michael Weinstock explains, the foam geometries of cellular materials offer open and ductile structural systems that are strong and permeable, making them an attractive paradigm for developments in material science and for new structural systems in architecture and engineering. MORPHOLOGICAL STUDY OF BONE DEVELOPMENT Results of a morphological study of bone development in pigs show similar behavior to what we found in our simulations. (A) The initial IMAGE, SCHEME: HTTP://WWW.ARNOPRONK.COM
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A
6 weeks
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Pigs, vertebral & prox. tibial specimens 2 mm B
configuration is porous and fine and becomes coarser and obtains more directionality when it matures. (B) Initially the volume fraction (VF) rises 0.0 0 100 200 sharply, overshoots and then weeks of age stabilizes (Tanck et al., 2001). (Note that maximal VF is not equivalent to peak bone mass). BV / TV 0.4
2 MPa cyclic load with frequency 1 Hz Modeling
a
b
Remodeling
c
d
Development of a 3-dimensional trabecular architecture as governed by external forces, starting from the porous initial configuration
RESEARCH - OPTIMIZATION
illustrated in (a), and the configuration after 10, 30 and 200 iterations (b-d). INDIRECT OSTEOBLAST-OSTEOCLAST COUPLING THROUGH MECHANICS Mechanical load LC
OCY OCY
Region of elevated mechanical signals
μdam μ dam
new LC
OBL
OCL
New bone with new OCY’s
the same precision as well.” Therefore structure (design, model) take over more than just structural logic system of bone tissue, but also certain processes in it. By combining biomimicry with mathematic patterns for building technology some benefits have been explored. Some opportunites are saving energy, cut material costs, minimize waste. By making use of structures deriving from nature, like the bone structure, it is possible to construct forms that have an innate optimal geometry.
Recruitment stimuli
Homeostasis
Microdamage triggers osteoclasts
Osteocytes recruit Osteoblasts
Homeostasis
During remodeling osteoclasts are attracted towards the trabecular surface due to microdamage. They produce a resorption lacunae resulting in local stress and strain concentrations surrounding the resorption cavity due to mechanical load transfer. Consequently osteocytes sense higher mechanical signals and recruit osteoblasts that form bone until the resorption cavity is filled. Some of the osteoblasts are encapsulated in the tissue matrix and differentiate to osteocytes. Other osteoblasts become inactive lining cells that cover the bone surface. Finally the homeostatic configuration is restored. CONCLUSIONS Remodeling of damaged bone tissue may be interpreted in context of my thesis project as described in Theses Abstract: “workflow get the ability to immediately edit just created 3D digital models and physical prototypes as well at the same time. For example, the use of CNC-milling provide precise process of subtracting the physical model, and by CNC-additive process like 3D printing you can add a new elements to the model with IMAGE: HTTP://WWW.74FDC.WORDPRESS.COM
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BONE STRUCTURE BONE STRUCTURE TEST Using micro computed tomography, we are able to reconstruct the microstructure of bone tissue and to obtain high resolution 3D images of FEM tests. It show us internal structural strength of bone tissue. One can simulate the behavior of the bone tissue under certain static or dynamic loads and detect/predict osteoporosis-induced fractures. “Efficient solution methods for trabecular bone micro-finite element models”.
CELLS WIREFRAME
HEALTHY BONE TISSUE
MESH
INJURED BONE TISSUE
BONE STRUCTURE MICRO-FEM MODEL OF BONE TISSUE (3D VOXELS)
IMAGE, SCHEME: HTTP://USER.IT.UU.SE/
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DENSITY
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PERSPECTIVES EXPANDING POSSIBILITIES
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CNC-MILLING
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PERSPECTIVES
CNC-MILLING
EXTRYDER WITH CNC-MILLING SYSTEM SPINDLEHEAD
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PERSPECTIVES
SUBTRACTING WITH CNC-MILLING As I mentioned in thesis abstract, using CNC machines in this interactive environment greatly increases the efficiency of the process - lets immediately create a physical rapid prototype of the design. A relationship between the "eyes" of the computer and CNC machine technologies open up a new platform for interaction. Workflow get the ability to immediately edit just created 3D digital models and physical prototypes as well at the same time. The use of CNC-milling provide precise process of subtracting the physical model. In this case I propose to use plate where the extruder is fixed as an universal for fixing there many differenrt devices. We need to have universal fixation points. CNC-milling system spindlehead is one of them. It has constrauction allows to come up only when it needs by moving up and down in Z-axis on the plate. Thus we use it only when we need subtract some part out of model. CNC-milling system main parts: _milling spindlehead DC motor; _drill: _stepper motor for moving up and down the spindlehead motor; _support structure with rails.
CONCLUSION During the design and constructing of our own 3D printer, its became obvious that a 3D printer with frame system is restricted in useage much more comparing to multi-axis Kuka Robot. Built 4D-based CNC robot is rather difficult approach even for mechanic engineers, not only for student of architectural faculty as we are. But such robots gives much more freedom for applying different devices on it and wider research field.
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PERSPECTIVES
CNC-MILLING SCENARIO Since I got physical object 100% equal to my digital 3D model I’ve designed, I can continue working on it further. Lets assum scenario. I’m satisfied with result of my SKETCHBOX modeling, but I need to edit it after fabrication. Here is how could looks like scenario for it: _upload mesh model of design; _turn on points mode; _by manipulating with hands choose points for editing; _pull&push them to get nessesary result; _subtracting zone definitedl; _put the model back to CNC machine; _run milling process; _enjoy the result.
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MILLING PROCESS
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SketchBOX CONCLUSIONS
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Architecture dealing with the future. As materials getting improve, new materials descovering it gives to architect new ideas. New machines coming on the market - it give next jump in arhitecture. Have an interface between all this descovers in workflow opens huge field for new possibilities. 3D digital interface field provide a mechanism for two or more people or even machines from distributed locations to work together in a virtual 3D environment as if they were in the same place. It gives a way to create convincing "avatars" of remote participants to be displayed at each site to support natural interaction. It gives more natural interaction with digital area as well. Prototyping is an expensive but necessary stage of a new product. To reduce the cost of making several prototypes and shorten the time-to-market, it is welcome when the design is right the first time. Redesigning or retooling when prototypes or even the first production batches do not comply with standards is very expensive. It is time consuming and it also delays the time-to-market for the new product. Rapid prototyping interface in combination with a lot of real world experience are the ways to reduce these delays. SketchBox project bring new methods of working, realize and materialize ideas for architects, industrial designers and artists.
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BIBLIOGRAPHY
1) R. Ruimerman - "Modeling and remodeling in bone tissue"; ISBN 90-386-2856-0 Univ.Press Facilities, Eindhoven 2005. 2) M. West, “Fabric-formed concrete columns”, Centre for Arch. Structures and Technology, Manitoba. 3) Greg Borenstein - "Making Things See", ISBN: 978-1-449-30707-3; O’Reilly Media, Inc., Canada 2012. 4) Dan O'Sullivan and Tom Igoe - "Physical Computing", ISBN: 1-59200-346-X; Thomson Course Technology PTR, USA 2004. 5) Michael Stacey - "Prototyping Architecture", ISBN: 10 – 0-901919-17-9; Building Centre Trust, London 2013. 6) Daniel Shiffman - "The Nature of Code"; USA 2012. 7) Architectural Design - ”Techniques and Technologies in Morphogenetic Design”; ISBN: 978-0-470-01529-2, 2006
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