BEN ROBINSON [Re_Map]1090
ii
Welcome To
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Print Ville
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DUS ARCHITECTS The KamerMaker Dutch: The Room Maker
THESIS PROJECT
The StadMaker Dutch: The Town Maker
Contents
0.1
01-19
Step 1- The System
20-23
Step 2- Pick Your Volume
24-45
Step 3- Pick Your Plot
46-51
Step 4- Customisation
52-79
Step 5- Interior Customisation
80-95
Step 6- Housing Standards
96-113
Step 7- Unit Development
114-159
Appendix-
160-163
Not Just a House
Your Printed Home
Imagine a new way of thinking
££££
££££
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Imagine a housing system where the driving force behind the price of a house was simply the weight in material used to produce it, where the traditional house on the left cost the same as the elaborate house on the right. This is now the reality with
StadMaker 3
StadMaker If you can think it We can print it!
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We welcome you to view StadMakers revolutionary new housing system 5
Imagine a place where you could 3D print a new chair or table for your house whenever you wanted.
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StadMaker’s PrintVille Here is your opportunity to reserve a plot and become part of the world’s first 3D printed housing community.
StadMaker Bloom / Emergin Objects 5Story Apartment Building // RMIT Quake Columns // Emerging Objects Steel Structural Node // Arup 3D Printed House // BetAbram 10 Houses in a Day // WinSun 3D Print Canal House // DUS Architects Endograft // StudioSmith CyBe Digital Grotesque // Hansmeyer + Dillenburger Nematox System // Holger Strauss ProtoHouse 1.0 // Softkill Design KamerMaker // DUS Architects Stone Spray Robot // IAAC Organic Printed Brick // Biomason
Year
Planter Brick // Rael San Fratello Architects Radiolaria Pavilion // D-shape +Shiro Freeform Construction // Loughborough IMCRC D-Shape Printed // Enrico Dini
Contour Crafting // Dr. Khoshnevis 99
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StadMaker, in association with DUS Architects, introduce you to
PrintVille the world’s first 3D Printed community, which will bring production back to the heart of Runcorn. 7
This is not 3D printing for the sake of 3D printing
Conventional
MANUFACTuRING
PROTOTY
DESIGN TIME
MANUFACTURING
DESIGN
PROTOTYPE
3D Printing
No difference in cost or time.
MULTIPLE Prototypes produced cheaply and quickly for field testing.
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If all designs were prototyped the cost would be quadrupled and assessment would take place one at a time
{
x4 TEST
FEEDBACK
x4 TEST
Only ONE design is selected for prototyping due to cost, time and tooling.
FEEDBACK
=
YPE
TESTING
TESTING
PRODUCTION
=
} TEST
FEEDBACK SIMULTANEOUS Testing of all prototypes means data is rapidly fed back into the process and quickly tailored to suit application.
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PRODUCTION
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Interested?
Come and take a tour
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This ground breaking project will be rolled out across Runcorn over the next decade - the first phase of which is on site now. There are still over 20 plots remaining, so come work along side us to create not just your future house, but your printed home.
B1
B2 12
StadMaker Future Masterplan 1:5000 at A1
Key
D4
Production Facility
Phase 1 On site
D3 D1 C3
D2
B
Phase B 2017
C
Phase B 2018
D
Phase C 2019
c4
C2
Future printed Housing
B3 Communal facilities
B4 C1
School
13 N
Phase 1- Growth
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Feedback
Complexity
Print size
Cluster Size
Time- 2015
Phase1-A The Sculpture Park, the first of the 3D prints are exhibited to the public to encourage a greater understanding of the technology that is being introduced to Runcorn.
Phase1-B The first and smallest cluster is now complete, home to houses designed by our partners DUS Architects.
Phase 1-C & D On site Now The first of the full size printed community clusters.
Late 2016
Phase 1-E- Taking Orders Now!
Phase 1-F- The Printed Apartment complex
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What will you see in a 3D printed community cluster?
Th Av e 20 ail 3 ibl e
Clu ste rO rbit al Ro ad Pl
ot
Sh
ar
ed
Pe
de
&
Ca
rR
The 101 Availible
ze
To
str
ian
Si
k La e h t
e
ou
te
ce
al
m
m
Co
un
a Sp
Plastic to PrintRecycling point
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Orbital Road To reduce car traffic, orbit roads navigate around each cluster creating a safe and quiet internal environment.
Plot Size - Your plot, your rules. If you want space to park 2 cars outside your house, no problem. If you want a printed climbing frame for your children, no problem. As long as your planned work does not breach any of the rules within the rule book, you are free to include what you want.
KamerMaker Once your 3D printed house is delivered, the 3D printing does not need to stop. At the centre of each cluster is a KamerMaker 3D Printer, allowing you to print furniture and upgrades for your house easily, just meters from your front door.
Shared Pedestrian & Vehicle route, These shared spaces are proven to create safer spaces for pedestrians and help to form a safe and pleasant environment.
Plastic to Print Recycling Point. Each cluster has direct access to the plastic recycling point where plastics will be melted down and recycled into print filament to be used in the communal KamerMaker.
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You can become a part of PrintVille in 7 easy steps
?
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Step 1 // Understand how the system works Being involved requires a higher degree of participation than your average new build, so it is important you understand the process before we get started.
The
203
Step 2 // Pick Your Volume
The
The 169
The 101 Plot Available
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Why be limited to a 2 bed or a 3 bed home? Pick from - the 203, the 169 or the 101 - and shape it to suit your individual needs.
Step 3 // Pick Your Plot Choose from the available plots for each of the three volume sizes.
Step 4 // CustomisationWork alongside StadMaker to start shaping your truly individual printed home.
Step 5 // Internal CustomisationWhether you want to embrace plastic furniture or stick to something more traditional.
Step 6 // Material Choice Print material can be mixed with a library of different additives to get the colour and effect you are looking for. If you use recycled material you may even be eligible for a government grant.
Step 7 // Production and assembly Your 3D printed home is now ready to be assembled on site.
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The System 21
System diagram
Clients can work along side a design team to help guide the production of customised elements.
As each house is customised and therefore different. There will be experiences to be taken from each house produced with improvements feed back into the system. Resulting in constant real time R&D which is current unachievable with current construction methods
This Diagram describes the process you will go through as a client in the process of designing and printing your very own home.
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The design and Customisation system caters for the selection of the housing modules as well as the Customisation of elements or selection of pre designed elements from a database.
Within the printing stage, print materials can be selected and configured for printing. The weight of the printed produced can then be determined.
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24
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Pick Your Volume
The volumes 203
The
203m2 GF- 67 1F- 68 2F- 31 Roof Garden- 32
The
The 169
169
The
The 203
101
169m2 GF- 61 1F- 39 Roof Garden- 23 2F- 39
The 101 101m2 GF- 45 1F- 46
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Three contrasting volumes that aim to cater for a wide variety of individual needs. The increase in size does not need to correspond to an increase in the number of bedrooms. Perhaps you work from home? Or simply enjoy open plan living. The 203 can be configured as a 2 bed with a office or a 4 bed house. The choice is yours. 27
From a volume to a customised home 203
The
Initial Volume
11000 3240
3240
250
The 203
2350
3600
2350
Brain 2 m²
The 203 WC 3 m²
Pre-customised floor plans
7800 2350
The 203 G Floor 62 m²
4040
2350
2020
3300
4040
4450
3950
250
3950
2000
Customisable parameters
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STADMAKER
Please refer to the separate rule book for a full explanation of all the rules.
_Rule Book
The Rule Book defines the elements and parameters for customisation within each of the three volumes. It is important to familiarise yourself with the rule book, but don’t worry, you will not be left alone to customise your home. The StadMaker team will work alongside you to ensure your design meets all the requirements of the rule book.
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The rule book Examples
CUSTOMISATION RULE 00: Customisation freedom is catered for as long as the said customisation does not impact negatively on the final sustainable code rating.
01:
Customisation that aims to improve the sustainable code rating is encouraged and supported.
Rule 02: Wall Zones
Cust Surface
External walls consist of 3 key zones. The customisable zone, controlled zone and structural zone. Understanding these zones is the first key step in understanding how customisation takes places within your STADMAKER Home.
Structural Element Controlled surface servicing insulation
Wall depth
Rule 03: Customisation Depth
450 115
The standard depth of an external customised surface is 115mm. There is 300mm of additional customisation depth available. Any distance beyond this will extend too far into surrounding land. The nternal customisable depth is 60mm, however this includes only internal wall finish and does not take into account printed items such as storage and shelves. 300
275
60
115
450 Max Cust Depth
Rule 04: Window Location & Size The allowed location of windows are shown in white. No matter what the size of the allowed opening (in this example 3950mm) the maximum span of a single window is limited to 2000mm due to the nature of the construction. Other than this the shape of a window is not controlled.
3950
2000
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Rule 07: Door Locations The allowed locations of external doors are shown in blue. Their positioning along this stretch will depend on your chosen interior layout. This is something your project Architects will work alongside you to set out.
Rule 08: Circulation Space The location of circulation space internally is not governed. However, circulation must be 1000mm at its narrowest point. This ensures housing meets the standards set out in Homes for Life.
Living Space
Printed Storage Unit
1000mm
Rule 10: Location of The Brain The location of the Brain is fixed. This allows for a set location for services to be installed on a plot and into a house. Brain
Rule 11: Location of Wet Services
Brain
WC Eat
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Kitchens, toilets and bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.
The Brain
Understanding the plans:
11000 3240
3240
250
The 203
2350
3600
2350
Brain 2 m²
The 203 WC 3 m²
2020
G Floor 62 m²
The only predefined space 2350
2350
The 203
4040
3300
4040
4450
3950
250
3950
2000
Brain
WC Eat
Rule 11:Location of Wet Services Kitchens, Toilets and Bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.
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The Brain is the only space with volumes that are predetermined. This is because it is the point at which services enter and exit your home. By keeping the Brain in the same place in every home, it makes the process of installation and maintenance more efficient. For technical information regarding the Brain please refer to step 7.
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The 203
Please refer to the rule book for the key and full set of rules relating to floor plans.
The
203
11000 3240
3240
250
The 203
2350
3600
2350
Brain 2 m²
The 203 WC 3 m²
The 203 GF
7800
67m2
2350
The 203 G Floor 62 m²
4040
2350
2020
3300
4040
4450
3950
250
3950
2000
275 300 125 50 450
2750
300
2000 2800
2050
The 203 Section 300
2800
2050
450
3260
375
3260
450
0
5 34
11000 250
3235
2350
300
68m2
7800
The 203 1F
2445
2350
855
3240
1st Floor 68 m²
2350
3300
2350
The 203 10100
3950
250
3950
2000
11000 250
3235
2350
300
31m2
7800
The 203 2F
2445
2350
855
3240
1st Floor 68 m²
2350
3300
2350
The 203 10100
3950
250
3950
2000
3240
3240
2000
32m2
4000
4000
The 203 Roof Terrace 32 m²
11000
35
2160
2160
2nd Floor 31 m²
250
The 203 Roof
The 203
The 203
Looking for something more traditional?
The
203
No problem! If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes. Just ask one of our representatives for more information. 36
The 203
Example of a traditional configuration (Not to scale)
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The 169
The
Please refer to the rule book for the key and full set of rules relating to floor plans.
169
9140 2000
9200
2085
1485
3455 7550
1480 3445
3860
1195
The 169
The 169
G Floor 61 m²
The Brain
The 169A
The 169A
2 m²
3 m²
Brain
The 169A G Floor 58 m²
WC
1510
2 m²
4015
2450
3150
4240
2570
2485 1650
825
825
2485
3860
1200 5770
3105
The 169 GF 61m2
460
2700
300
2800
300
2800
The 169 Section 450
5300
375
3260
325
0
5 38
The 169 1F 39m2 RG- 23m2
3650
5750 3850
540
3675
The 169
The 169 Roof Terrace 23 m²
The 169A
The 169A
1st Floor 40 m²
Roof Terrace 26 m²
1650
3035
2140
2140
9200
1st Floor 39 m²
4310 7550
1195
3160
3160
3065
3850
3860
3860
2000
2000
The 169 2F 39m2
3850
The 169
3160
3160
3060
3850
The 169A
2nd Floor 39 m²
3860
3160
3035
3160
2nd Floor 40 m²
3860 2000
2000 5750
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The 169
Looking for something more traditional?
The
169
No problem! If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes. Just ask one of our representatives for more information. 40
The 169
Example of a traditional configuration (Not to scale)
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The 101
Please refer to the rule book for the key and full set of rules relating to floor plans.
The
101
7615 2000
2000
2710
2640
2450
2740
2740
2450
The 101A
3775
Brain
The 101 G Floor 45 m²
The 101
The 101
Brain
Store
1 m²
1 m²
The 101A
2 m²
7550
3200
G Floor 45 m²
The 101A WC 2 m²
2075
WC
4825
1910
The 101
3545
3 m²
2525
200
2475 1650
860
860
2785
2525
The 101 GF 45m2
500
2000 2850
300
2800 2050
The 101 Section 45m2 450
3150
375
3450
325
0
5 42
2000 2450
The 101A
The 101
1st Floor 43 m²
2825
1030
3540
1st Floor 46 m²
The 101
The 101A Balcony 7 m²
785
Balcony 4 m²
2525
The 101 GF 46m2
43
4125
2730
2640
5360
2215
3675
2190
2730
1110
The 203
Looking for something more traditional?
The
101
No problem! If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes. Just ask one of our representatives for more information. 44
The 101
Example of a traditional configuration (Not to scale)
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46
Pick Your Plot 47
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Developed Plots
The DUS House
The Wood House
The Normal House
The Wavy House
The Solar House
The Blob House
The Purple House
The Tudor House
The Artists House
Available Plots 203
The
The 203
The
169
The
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101
The 169
The 101
Why not take a walking tour of the site to see the houses that have already been printed.
Looking for inspiration?
Then take a look at this elevation of a completed street... The
203
The 203 ‘The Normal House’ The Smith Family
The
The 169 169
‘The Solar House’ Dr Yvonne Grunder
The
The 169 169
‘The Artists House’ Tom Gilmour
The
101
The 169 ‘The Tudor House’ The Buckets
StadMaker Elevation 1:100 at A1
Each of these completed houses are strikingly individual, yet all meet the requirements set out in the rule book. If you can think of it, we can print it!
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Customisation 53
How does it work?
Our state of the art software can take your photographs and images and translate them into a 3D form in 7 steps.
A brick Wall? We can print it
You like Erwin? We can copy it
Or you want to advertise you art On your house? We can do it
Step 1- Send us your image
Step 2- Translate image
Step 3- Select your volume
If you have a design in mind, whether it is your favourite piece or art or architectural style, simply email it to us atPrintville@stadmaker.co.uk
Our software will translate your images into a bitmap file. This allows us to set the level of extrusion based on the colour shade from white to black.
The 203, The 169 or The 101
Step 4- Scripted Design
Your selected design can then be applied to your chosen volume using o advanced script-based modeling tha has been developed in house.
our at
Step 5- Design consultation
Step 6- Printing
Step 7- Assembly
Through a series of design consultations, your design will be honed until you are happy.
Once the design has been finalised it can be sent to the on-site printers.
The printed elements will then be transported to site and assembled in less than one working week.
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How does it work?
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This method allows us to simply overlay your designs onto the predefined facade structural elements. This allows for infinite variation in design, whilst the structural system remains the same throughout. For more information on the structural system please see step 7.
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The Art House
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What will yours say about
You?
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Existing clients Client Bio Tom Gilmour- Artist. Tom is a artist who grew up in Runcorn. His tattoo-inspired art has led him to do work for numerous clothing lines as well as launching his own websitehttp://www.tomgilmour.com Tom was looking to design a house that was not only a personal statement but also a house that advertises his own work.
Bespoke artwork Tom created a bespoke piece of art that was drawn specifically to be turned into the facade of his future house. Working alongside Tom, we draped the artwork around the 169 volume to create a totally unique design.
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Client Specific customisation parameters
Artwork Scale Extrusion Depth Displacement Angle
User interface Our software has a simple and intuitive user interface that Tom got stuck into when designing his house.
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Drape
What if you don’t have a design in mind?
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If you don’t have a design idea for us to work with, you can still create your dream home using our other modes of customisation: 1- StadMaker database 2- In-house environmental modeling 65
Existing clients Client Bio Mr & Mrs Smith The Smiths where born and bred in Runcorn. Alan Smith worked at the local gas plant until it shut down and was forced to retire.
“All i want is a traditional detached house with room for the grandchildren� Having lived in a rundown ex-council house that is being demolished as part of the PrintVille regeneration work, the Smiths have what many would consider a simple wish - and that is to have a traditional detached brick house.
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149 110
Using the StadMaker online database Export
MakerStad
Online Database
Load File
Facades
Finishes
Furnishings
Artwork Scale Extrusion Depth Displacement Angle Drape
The Smiths took advantage of our online database of image samples, including numerous images of brickwork buildings from Runcorn Old Town. The Smiths were able to select their favourite design elements to form their dream house.
Specific Customisation Parameters
Brick Type A
B
C
D
Brick Pattern The material choice is key to the aesthetical finish of the house and brick dust from the recycled brick will be used to create a brick-like texture. (See Step 6 for more information)
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A
B
C
D
Window Type A
B
C
D
The Normal House
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What will yours say about
You?
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The Solar House
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Other ways to customise your home
Client Bio Dr Yvonne Grunder Is a Doctor of physics at the Stephenson Institute for Renewable Energy at the University of Liverpool.
Dr Grunder has been involved in the installation of PV systems across the University campus. Her passion is renewable energy, particularly PV Arrays. She has seen the StadMaker project as a means to take her passion for work into the form of her home by using our environmental modeling software.
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Environmental modeling MakerStad
Analysis Software
Load File
Peak Radiation
<
>
Value Range: 110.0 - 500.0 Wh/m2
+
-
Modeling space
Wh/m2 500+ 461 422 383 344 305 266 227 188 149 110
Export
MakerStad
Online Database
Load File
Facades
Finishes
Furnishings
1//
Once you have selected your plot we take the exact latitude and longitudinal co-ordinates of your plot.
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Environmental modeling 2//
Our adaptive solar facade panels are then placed into our environmental modeling software with the exact latitude and longitude co-ordinates. It then orientates them into individual facade elements to ensure each element is perfectly orientated to gain maximum solar energy.
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3// The software ensures each element catches maximum solar rays without blocking solar rays from its neighbours This means that every single house designed using this software is unique. As the individual latitude and longitude co-ordinates ensure this individuality.
See appendix for full results
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Enviromental modeling 2//
Wh/m2 500+ 461 422 383 344 305 266 227 188 149 110
3//
Wh/m2 900+ 840 780 720 660 600 540 480 420 360 300
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4// Wh/m2 800+ 732 664 596 528 460 392 324 256 188 120
5//
Wh/m2 800+ 730 660 590 520 450 380 310 240 170 100
6//
Wh/m2 800+ 732 664 596 528 460 392 324 256 188 120
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1:20 Facade components
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Interior Customisation 81
StadMakerâ&#x20AC;&#x2122;s online database Furnishing
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Embrace the plastic! We have a database of 3D printed furniture that we can print as part of your home design. Here are a few examples. Or work alongside us to design your own. 83
The Bedroom Unit
Open plan bedroom Do you like the idea of open plan living? Why not turn your bedroom into a grand open space with this integrated bedroom and bathroom unit?
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The Potato Wall
Green fingers Do you like growing your own food? What if you could grow potatoes in a wall that has been 3D printed in a bioplastic that contains 30% potato starch? With StadMaker you can!! For information on potato filament please see step 6
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The Print Desk
Working from home? Or do you just enjoy printing? The print desk is an elegant 3D Printed desk that literally grows out of the walls it sits against. This may seem strange, but with 3D printing we can literally incorporate furniture into the walls and print them as a single element.
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The Stairs
They donâ&#x20AC;&#x2122;t need to be normal. Stairs are often simply just a functional element. But they donâ&#x20AC;&#x2122;t need to be. With Stadmaker, a bespoke staircase costs the same as a plain one - you just pay for the material you print!
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Or something for the 3D Print enthusiasts with open(filename, “w”) as f: for line in lines: if not (‘M84’ in line or ‘M25’ in line): f.write(line) if ‘FLAVOR:UltiGCode’ in line: #Flavor is UltiGCode! No reset of values no_reset = 1 if ‘;TweakAtZ-state’ in line: #checks for state change comment state = getValue(line, ‘;TweakAtZ-state’, state) if ‘;Small layer’ in line: #checks for begin of Cool Head Lift old_state = state state = 0 if (‘G4’ in line) and old_state > -1: state = old_state old_state = -1 if ‘;LAYER:’ in line: #new layer no. found layer = getValue(line, ‘;LAYER:’, layer) if targetL_i > -100000: #target selected by layer no. if state == 2 and layer >= targetL_i: #determine targetZ from layer no. targetZ = z + 0.001 if (getValue(line, ‘T’, None) is not None) and (getValue(line, ‘M’, None) is None): #looking for single T-command pres_ext = getValue(line, ‘T’, pres_ext) if ‘M190’ in line or ‘M140’ in line and state < 3: #looking for bed temp, stops after target z is passed old_platformTemp = getValue(line, ‘S’, old_platformTemp) if ‘M109’ in line or ‘M104’ in line and state < 3: #looking for extruder temp, stops after target z is passed if getValue(line, ‘T’, pres_ext) == 0: old_extruderOne = getValue(line, ‘S’, old_extruderOne) elif getValue(line, ‘T’, pres_ext) == 1: old_extruderTwo = getValue(line, ‘S’, old_extruderTwo) #Ex3 elif getValue(line, ‘T’, pres_ext) == 2: #Ex3 old_extruderThree = getValue(line, ‘S’, old_extruderThree) if ‘M107’ in line: #fan is stopped; is always updated in order not to miss switch off for next object old_fanSpeed = 0 if ‘M106’ in line and state < 3: #looking for fan speed old_fanSpeed = getValue(line, ‘S’, old_fanSpeed) if ‘M221’ in line and state < 3: #looking for flow rate tmp_extruder = getValue(line,’T’,None) if tmp_extruder == None: #check if extruder is specified old_flowrate = getValue(line, ‘S’, old_flowrate) else: if tmp_extruder == 0: #first extruder old_flowrateOne = getValue(line, ‘S’, old_flowrateOne) if tmp_extruder == 1: #second extruder old_flowrateOne = getValue(line, ‘S’, old_flowrateOne) if (‘M84’ in line or ‘M25’ in line): if state>0 and speed is not None and speed != ‘’: #’finish’ commands for UM Original and UM2 f.write(“M220 S100 ; speed reset to 100% at the end of print\n”); f.write(“M117 \n”) f.write(line) if ‘G1’ in line or ‘G0’ in line: newZ = getValue(line, ‘Z’, z) x = getValue(line, ‘X’, None) y = getValue(line, ‘Y’, None) if (newZ != z) and (x is not None) and (y is not None): #no tweaking on retraction hops
For the full code please see the appendix
With this script we have devloped in house, we have taken a common 3D print error- under extrusion , and transformed it into a controlled method of creating beautiful and function partionwall and railing. 88
Not only is it more beautiful that a generic wall but it uses up to 70% less material due to its bone like structure. 89
The Under Extruded Wall
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Potatoware
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Why stop with the stairs?
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Embrace the plastic
Here at StadMaker we hope you embrace the plastic in the same way as Dr Yvonne Grunder. Every item you can see in this photograph has been 3D printed specifically for the solar house. Dr Grunder was dedicated to maximise the use of recycled plastics within her design to gain the highest possible sustainability rating.
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Concrete screed floor with recycled plastic scrap aggregate
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â&#x20AC;&#x153;Keystonesâ&#x20AC;? 3D printed Table designed by friends of DUS Architects Studio Minale-Maeda
Potatoware By Ben Robinson & DUS Architects
Or remain traditional
A StadMaker home does not need to look like something from the future. We understand that people have their own taste, style and favourite belongings. Therefore your StadMaker home does not have to have the look and feel of plastic. You can finish it with traditional materials or use special printing techniques to recreate traditional materials.
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Traditional table printed in mahogany additive plastic filament
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Shag pile carpet
Picture hanging can be incorporated into the printed walls
Wallpaper can be easily applied to our printed walls or you could even print the pattern
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Material Choices 99
What is Bio Plastic / PLA?
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Product By
ac Extr tion
w Mater ia Ra
Refining
l
w Materi a Ra l
la BioP stic
Renewal
Disposal
duction Pro
PLA - Poly(lactic acid) or polylactide A form of bio-plastic, particularly a biodegradable thermoplastic (under specific industrial conditions). It comes from renewable plant resources, such as corn starch, tapioca roots, sugarcane chips or any other high starch foods. In 2010, PLA had the second highest consumption volume of any bio-plastic of the world.
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How is it made?
Colorfabb
Small Scale Production Line
Raw material heater and Extruder
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Material extrusion and cooling
Laser monitored quality control procedure
Our Material Partners based in the Netherlands have developed a system to mass produce additive based bio-plastic allowing us to quickly and easily add colour material additives to create the finish you desire. 103
<70%
<30% 104
How do you add colour / materials? Base Material
Macromelt 6900E a non hazardous and biodegradable bio-plastic (biodegradable in specific conditions, not under normal use).
Additive material
If you can think of it we can add it (exclusion apply to hazardous additives or additives that could impact upon the structural integrity of the plastic).
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Material mix
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Base Material Macromelt 6900E is a near translucent base material.
Additive MaterialRecycled car tyres This ratio of tyre pellets to Macromelt 6900E is all that is needed to change the colour of the plastic from translucent to a deep black. Additional tyre material can be added up to a value of 30% to bring out the texture and feel of rubber to the printed surface..
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The Solar House Material makeup Printed layers- 9135 Base material- Macromelt 6900E derived from Dutch Linseed oil. Filler Material- 7 Local sourced recycled materials
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The Normal House Material makeup Reminisce
Locally sourced additive material
The Smiths reminisced of the houses they grew up in as children - traditional two up two down.
Bricks were collected from houses demolished within the Runcorn area.
The Runcorn brick print filament
The brick is then ground down into dust and mixed with the Macromelt 6900E to form the Runcorn Brick Filament
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1:20 Structural Model
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The Tudor House Material makeup The unaffordable wish - Halton Village
StadMaker picture mapping
The Buckets have always dreamed of living in Halton Village, but have simply not been able to afford a property.
But now StadMaker is able to recreate their dream home by photo-mapping the surface of a tudor house and recreating it in our state of the art software.
UK sourced waste oak wood shavings
We sourced oak wood shavings from a UK based furniture manufacturer to recreate the tudor style of the past with the home of the future.
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1:50 Model
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Material choice
Whatever your style, we can find and develop a colour or material that is personal to you. 114
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Production & Assembly 117
The KamerMaker V1
The KamerMaker is the 3D printer developedbyDUSArchitectsthat inspired StadMaker along with DUS to develop The StadMaker and begin production of housing on a much large scale. 118
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The KamerMaker (Room Builder)
The KamerMaker is simply too small to be used for the full scale production of the housing components, but instead it is utilised at the center of every housing cluster as a communal 3D printer.
3100 16 00
00 16
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The StadMaker (Town Builder) 9 Print heads combine to form one super quick 3D printed increase print speed by 90%.
The StadMaker measures in at double the print bed size and an increase in 600mm in buildable height.
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Yes thats right, our innovative construction system can really save 75% on raw materials. By using state of the art software andbyutilisingthemanybenefits offered by 3D printing, we are able to optimise the structure to only place material where it is structurally required. 122
75%* Reduction in Raw Materials With our innovative optimised Structural system *Average saving 65%
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The structural system 1:20
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Structural system // Macro 1
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Print element Junction
The 203 Brain 2 m²
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The 203 WC 3 m²
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The 203 G Floor 62 m²
Structural column
Structural lintel 10
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Printed structural elements in The 203 GF- 12 1F- 12 2F- 10 RG- 6 R- 8
Largest printed panel 3600, 3100, 450 mm
Although the Stadmaker construction system utilises world leading technology, the underling structural system is based on simple and traditional construction methods. The facade elements simply slot round the structural system of columns, beams and lintels that support the overall load of each 3D printed house.
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Structural system // Meso 1:10
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Structural system // Micro optimised columns 1:20
Pre-optimised form
Displacement: Max 2.083e-00m
Support material
3D printed mould of optimised form
Poured concrete structural infill 130
Displacement: Max 2.083e-00m
Tension & Compression
Factor of Safety
Max 2.000e + 02 MPa
Min -1.772e +02 MPa
Here you can see our optimising software in action. Material that does not carry load is removed to leave the most optimal and efficient shape (safety is monitored highly as shown above). This process saves
65% in material 131
Structural system // Micro optimised columns 1:20
Pre-optimised
Run 1 of optimisation
Run 2 optimisa
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of ation
Section
Showing poured concrete internally
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Final run
With facade panel fixings
Structural system // Micro optimised lintel 1:20 Pre-optimised form
Poured concrete structural infill
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Tension & Compression Max7.394e + 02 Pa
Min -1.667e +03 Pa
Displacement:
1
Max 1.483e-08m
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3
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70% material 135
savings
Structural system // Micro 1:20
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The structural system 1:20
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The structural system 1:20
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Structural axonometric The Solar House
1// External floor tiles (material defined by occupant) to protect the bottom of the printed walls from ground conditions.
2// Aluminum capping strip. 3// 280 x 360mm reinforced strip concrete foundation. 4// Passive slab- 3x EPS 100 rigid insulation, DPM, EPS 300 L element. 5// Concrete & recycled plastic aggregate screed flooring. 6// Printed ceiling panels. 7// HVAC ventilation system. 8// 10 x 35mm C profile ceiling clip. 9// Lighting designed by DUS Architects. 10// Electrical wiring modules. 11// D-175mm W- 225mm L4600mm 3D printed structural beam (developed by Contour Crafting (California)
12// Floor system- 10mm Ridigur fire protection, 15mm floor deck, 45mm floating sub floor, 15mm floor finish.
13// 3D printed wall system, minimum size 450mm x 3100mm. 14// Structurally optimised 3D printed column with poured concrete infill. 15// Structurally optimised 3D printed lintel with poured concrete infill. 16// Integrated PV arrays 17// Case of structurally optimised 3D printed column with poured concrete infill.
18// fixing junction for 3D printed wall elements to structural columns 19// 3D printed infill to wall system. The wave from is due to the need to only have material where it is structurally needed
20// 160mm deep recycled insulation containing shredded plastic from failed prints.
21// DPM 22// Integrated serving pipes, printed within the wall system 23// Integrated electrical modules - plug socket
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Printed & non-printed elements The Solar House
1// Case of structurally optimised 3D printed column with poured concrete infill. 2// Structurally optimised 3D printed lintel with poured concrete infill. 3// Structurally optimised 3D printed column with poured concrete infill. 4// 3D printed wall system, minimum size 450mm x 3100mm. 5// D-175mm W- 225mm L4600mm 3D printed structural beam (developed by Contour Crafting (California). 6// Lighting designed by DUS Architects. 7// Printed ceiling panels. 8// Concrete & recycled plastic aggregate screed flooring. 9// Integrated serving pipes, printed within the wall system. 10// 160mm deep recycled insulation containing shredded plastic from failed prints.
11// 3D printed infill to wall system. The wave form is due to the need to only have material where it is structurally needed. 12// Fixing junction for 3D printed wall elements to structural columns.
Key Fully 3D printed Printed composite Not printed
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MakerStadâ&#x20AC;&#x2122;s Printed Parts
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Printed wall profile Concrete wall 100% infill
Clad steel frame 60% infill
Printed wall 15% infill
Our wall profile uses 85% less material than a typical concrete wall. This translates as savings in your pocket whilst helping to protect the environment! 146
MakerStadâ&#x20AC;&#x2122;s Printed Profile
Pr in t
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Pa
th
How much does your house weigh?
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As your entire house will be modeled in our state of the art software, we are able to calculate the weight and therefore cost of your printed elements instantly. Meaning at StadMaker there are no hidden costs! You just pay for the material you use.
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How much does your house weigh? (Calculation are for printed facade elements only)
££££
5.3 metric tonnes ££££
4.4 metric tonnes
££££
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4 metric tonnes ££££
2.6 metric tonnes ££££
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Servicing strategy 1// Electrical switch and fuse box. 2// MVHR fresh air ventilation duct. 3// MVHR stale warm
air extraction duct.
4// Electrical wiring fed through floor trusses. 5// Services entrance point. All services enter ever house at a fixed point throughout The 203, The 169, The 101 volumes.
6// Combined ASHP space Heater and
MVHR unit.
7// Printed ceiling panels. 8// Concrete & recycled plastic aggregate screed flooring. 9// Integrated serving pipes, printed within the wall system 10// 160mm deep recycled insulation containing shredded plastic from failed prints.
11// 3D printed infill to wall system. The wave form is due to the need to only have material where it is structurally needed 12// Fixing junction for 3D printed wall elements to structural columns
As covered in Step 1, The Brain is the only room thats position is fixed within your design. This allows for quicker and simpler installation and possible repairs. 152
MakerStadâ&#x20AC;&#x2122;s Servicing Strategy
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The Brain
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Servicing strategy printed to non-printed junction
At StadMaker we have developed a system that allows for traditional appliances, fixtures and fittings to be incorporated into a 3D printed environment. So if you prefer the feel of porcelain, we have you covered. 154
Printed pipe Standard non-printed pipe Printed connection junction
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Pre-customised section 1:20 at A1
450mm default Width
Roof must be inclined to a minimum of 2 째 to allow for rainwater to run off the drainage channel.
Integrated service channels printed into the facade elements.
A channel on the external side of the wall elements collects rain water for harvesting
MVHR unit provides fresh air to the houses whilst removing stale warm air.
Small risers distribute services upwards and then horizontally above the ceiling.
Vertical junction between printed wall panels
The Bra
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MakerStadâ&#x20AC;&#x2122;s Section 1:20 at A1
Concealed guttering must be located on the lowest side of the roof
How will you customise yours?
ain
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Customised section 1:20
at A1
The Solar House
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MakerStadâ&#x20AC;&#x2122;s Section 1:20 at A1
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_Rule Book 163
What Will Your StadMaker House Look Like?
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The Rules are not in place to stifle your creativity, but instead to ensure that a well rounded and deliverable design for your future home is achieved.
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The Primary Rule CUSTOMISATION RULE 00: Customisation freedom is catered for as long as the said customisation does not impact negatively on the final sustainable code rating.
01:
Customisation that aims to improve the sustainable code rating is encouraged and supported.
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The Rules Rule 01: The Plot
Rule 02: Entrance
Customisable Surface
Controlled surface servicing insulation
Rule 03: Wall Zones Structural Element
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External wall consist of 3 key zones. The customisable zone, controlled zone and structural zone. Understanding these zones is the first key step in understanding how customisation takes places within your STADMAKER Home.
The Rules Wall depth
450
Rule 04: Customisation Depth The Standard depth of an external customised surface is 115mm. There is 300mm of additional customisation depth available. Any distance beyond this will extend too far into surrounding land. The Internal customisable depth is 60mm, however this includes only internal wall finish and does not take into account printed items such as storage and shelves.
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300
275
60
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450 Max Cust Depth
Rule 05: Window Location & Size The allowed location of windows are shown in white. No matter what the size of the allowed opening (In this example 3950mm) the maximum span of a single window is limited to 2000mm due to the nature of the construction. Other than this the shape of a window is not controlled.
3950
2000
Rule 06: Window Location Part 2 Windows are not allowed within either 250mm or 200mm (Volume Choice Dependant) of structural elements. This allows room for servicing to run vertically through the wall system.
250
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The Rules Allowed Window location
Rule 07: Window Location by Orientation The percentage of Window to surface is limited depending of the orientation of a given facade surface. For example, the maximum percentage of opening on a south facing facade is 45% of the total surface. On a north facade this is reduced to 15%. This is to limit unnecessary heat loss and help achieve a code 6 sustainable home.
45% South
30% East // West
15% North
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The Rules Rule 008: Door Locations The allowed locations of external doors are shown in blue. Their positioning along this stretch will depend on your chosen interior layout. This is something your project Architects will work along side you to set out.
Rule 09: Circulation Space
Living Space
Printed Storage Unit
The location of circulation space internally in not governed. What is governed is that circulation must be 1000mm at its narrowest point. This Ensures housing meets the standards set out in Homes for Life.
1000mm
Rule 10:Location of The Brain The location of the Brain is fixed. This allows for a set location for services to be installed on a plot and into a house.
Brain
Rule 11:Location of Wet Services Brain
WC
Kitchens, Toilets and Bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.
Eat
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The Rules Rule 12:Location of Governed Items Some items such as stair cases will be governed to a set corner of a floor plan. This may be for a number of reasons. Although not a set rule we encourage stair cases to be located against the north facing facade, as it is sensible for it to be located areas with a lesser need for natural light.
Rule 13: Roof Angle Roof design requires more work along side a Stadmaker designer. To ensure designs are structurally sound. The main governing rule is that there must be a minimum roof angle of 2째 to ensure a sufficient angle for rain water run off.
Rule 14: Rain Water Collection Rain water collection can be integrated within the roof or even the facade panels, as DUS Architects have done for their house design. Rain water collection must always be located on the lowest side of the roof.
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The Rules
Rule 15: Printed Junction The junctions between each printed panel must not altered through customisation. Their position and shape must be consistant throughout to ensure a small level of repetition that greatly increases the buildability and speed of the assembly.
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The Rules
Rule 16: Impacting your neighbour Customisation must not negatively impact upon the neighbouring properties.
Rule 17: Inappropriate customisation Indecent customisation is not aloud. Although freedom of expression is encouraged, StadMaker must draw the line at a point to ensure a pleasant living environment for everyone.
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Print Guides Encourage Discouraged
Unsupported Horizontal Surface These surfaces require support material to be printed in order to hold up the unsupported surface. This requires a considerable amount of material that will not be used in the finished item.
Inclined Surface These are encouraged as the material printed on the layer below supports the next layer to be printed meaning no unused support material is required.
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Print Guides
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As long as it fits we can print it. And if it doesnâ&#x20AC;&#x2122;t you can split it into multiply files and print it anyway! 175