Final Project Portfolio_Robotic Cera-cutting

M.Arch, Design for Manufacture (2021/22)

Bartlett School of Architecture, UCL

Robotic Cera-cutting

fig 01. Stereotomic assembly of ceramic prototypes

Thesis title

Thesis title

ROBOTIC WIRE-CUTTING OF CLAY

20111292

Harsh Manish Shah November, 2022

Forename, surname Month, Year

A design thesis portfolio submitted in partial fulfilment of the requirements for the degree of

A thesis submitted in partial fulfilment of the requirements for the degree of

Design for Manufacture MArch

Design for Manufacture MArch

(BARC0060: Final Major Project)

A submitted partial of the for degree for Thesis Forename,

Thesis supervisors: Forename, surname

Design tutors: Ben Spong Pradeep Devadass

The Bartlett School of Architecture

Faculty of the Built Environment | University College London UCL at Here East | Queen Elizabeth Olympic Park, London, E20 3BS

Bartlett School Architecture Faculty of Built | University London UCL at East | Elizabeth Olympic Park, London, E20

CONTENTS

01 02 03 04 05

Acknowledgement

Research Proposal

1.2 Problem Identification Subtractive Motion Toolpath Development

1.3 Motivation Design Application: Prototype

1.4 Contextual Background 1.5 State-of-the-Art 1.6 Key Project Intent 1.7 Aims & Objectives 1.9 Methodology 1.8 Research Questions 1.10 Research Plan

Project Chapters

100 64 32 124

07 10 118 04

fig 02. ‘The need for accuracy in material uncertainty’, Interpreting the feedback loop between the digital and the physical tool.

ACKNOWLEDGEMENT

The Final Major Project researchwork was led by the Director, Peter Scully whom I would like to thank for his academic, pastoral support and esteemed inputs from his industrial knowledge. Fel low collaborative support from colleagues, Bingze Li and Krit Chatikavanij has been immense.

Firstly, I am deeply indebted to my family for their motivation, especially my parents. The continu ous pastoral support from the UCL SPCS and Departmental Support Staff played an important role in ensuring smooth academics, including Claire McAndrew and Daniel Rodriduez.

I would like to express my gratitude to the Design Tutors for their academic guidance through these months. Pradeep Devadass for his grounded fabrication expertise that helped me test beyond the limits, Ben Spong, for his critical analytic and design thinking, that challenged the project scope.

The research would be impossible without the technical support of the BMade staff, ranging from digital guidance from Samuel Turner, YaoYao Meng and Guillem Olesti to physical assistance from Melis Berg, Lucy Flanders, Claudia Toma and AV support from Michael Wagner is commendable.

The most important contribution amongst the above is the intense help and support from my flatmates, Mounika Maddipatla and Dhruv Thakker, photographic documentation and multimedia presentation support from Sharif Mynasabgari, Yifan Shi and Satyam Gyanchandani. fig 03. The tool (robotic fabrication), the structure (stereotomic geometry) and the process (wire-cutting ceramics)

fig 04. Work-in-progress showcasing the wire-cut smooth surfaces versus the raw unprocessed natural clay block.

Project Showreel_preview https://youtu.be/E0XzlkV8dwI

1.0

RESEARCH PROPOSAL

The Research Project investigates the tectonic potentials of digital fabrication of robotic wire cutting (RWC) as a subtractive manu facturing process in architectural ceramics. The system focusses on the interrelationships between robotic production (the tool), stereotomic geometry (the structure) and wire cutting system (the process).

Given a block of local clay, the research uses a wire cutting tool as an end effector for a multi-axis robotic arm and through a series of experiments investigates the limits of the material behaviour, fabrication accuracy and geometric customisation. The learnings are accumulated to then define a subtractive motion planning workflow to produce optimised stereotomic assemblies.

How can digital fabrication achieve optimised construction sys tems, that deliver utility in low-tech economies with regional craft resources? This technique is then applied to produce a stereoto mic ceramic construction system for post disaster rehabilitation in clay rich seismic contexts, here, in the vernacular construction of Bhunga houses in the seismic locality of Kutch, Gujarat, India.

Robotic Wire-Cutting of Clay

fig 05. Digital Fabrication Workflow (testing from digital simulation to physical prototyping)

Digital Fabrication Workflow Development

1.2

RESEARCH PROPOSAL (Identifying Local & Global Challenges)

AEC Industry (Architecture, Engineering, Construction)

Identification of challenges and proposed solutions at the global level

1.2

01. Finishing and precision dependent on manual labour. 02. Intensive technology focus only for mass production. 03. Limited labour, resources for bespoke customisation. 04. Conventional wasteful subtractive moulding methods. 05. Restricted R&D in high tech manufacturing tools. 06. Superflous unsustainable material consumption.

Architectural Ceramics Industry

Identification of challenges and brain-storming solutions at the local level.

fig 06. “Goal 11 | Department of Economic and Social Affairs.”, UNSDG, https://sdgs.un.org/goals/goal11.

fig 07. Ceramic Production Documentation from Darwen Terracotta Factory by Bingze Li and Monisha Sridhara

RESEARCH PROPOSAL

(Problem Statement)

MANAGING RESOURCE CONSUMPTION

____Optimised Subtractive Production

IMPROVING PRODUCT PERFORMANCE

____Complex Geometry Variability

EFFICIENT MATERIAL UTILISATION

____Minimum Waste Generation

DIGITAL FABRICATION FEEDBACK LOOP

____Supply Chain Development Tooling

DFM

GEOMETRY Mass Customisation MATERIAL Usage Efficiency FABRICATION Quick Production

How can efficient digital fabrication platforms aid in ceramic agility and performance to ensure sustainable material lifecycle patterns?

Motivation: Digital Fabrication as a workflow

Strategising tools for finding solutions for the issues identified.

1.3

What are the other digital fabrication stakeholders that play key role in the workflow? - the tool, the process and the struc ture. Hence, contextual study within the realm of architec tural ceramics, is the next step in the research study process.

fig 08.Flowchart entailing the role of DFM (Design for Manufacture) in the digital fabrication setup

RESEARCH PROPOSAL

(Project Background)

Background of Architectural Ceramics

Contextualising the workflow within the realm of Architectural Ceramics

1.4

ROBOTIC FABRICATION STEREOTOMIC GEOMETRY

T tool structure S P process

For high volume-mass customised manufactur ing, one needs a production tool for prototyping iterations, precision and variability. Here, robots can be used to discretise the huge volume of variation in module geometry, support material efficiency by maximising stock-production ratio, aid in high-volume quick production by con trolling the material plasticity.

Stereotomy is an art of cutting masonry forms and rules to structurally assemble them. For high volume-quick production, the set of geometries can have micro-variations for being stereotomic. Can techniques be adapted on plastic clay based on how it wants to behave, how it can be worked, moulded, and transformed for suitable value propositions through ‘digital stereotomy’?

WIRE-CUTTING CERAMICS

There are contingencies involved in a simple, yet convoluted, contemporary manufacturing work flow that plies on the plasticity of clay. Specifical ly for architecture of volumes, can wire-cutting be tested on plastic clay to reduce the produc tion machining hours by single sweep removal and incur less tooling costs, yet a better surface finishes render an effective subtractive system?

09a. ‘Vernacular Ceramics’. BASE studio, “Flocking Tejas. Vimeo, 2022.”, https://vimeo.com/221798735.

09b. ‘Digital Making’. Interview with Mario Carpo, “DigitalFUTURES: Architecture and Automation, YouTube, 2020.

09c. ‘Physical & Digital Tools’. Research Paper by Wibranek, Bastian, et al. “Interactive Assemblies: Man-Machine Collaboration through Building Components for As-Built Digital Models.”

09d. ‘Architecture of Volumes’. Illustration from De La Rue, “Traitè de la Coupe des Pierres, 1728.”, pl. XXX (detail)

09e. ‘Robotic cera-Cutting’. Photograph by Harsh Manish Shah, Bartlett School of Architecture, UCL, London.

09f. ‘Value Proposition through meaning’. Quote from article by Michael Amundsen.

“Q&A With Juhani Pallasmaa on Architecture, Aesthetics of Atmospheres and the Passage of Time.”

RESEARCH PROPOSAL

(State-of-the-art Studies)

Learnings from the case studies

Integrating industrial robot within extrusion chain (existing production)

Variability in wire-cutting prototyp ing (suitable for mass customisation)

RWC as a quick production system for complex and volumetric geometries.

Studying the limitations and opportunities in Robotic Wire Cutting of Clay

P P

complex multi-dimensional set of trade-offs between material stiff ness, processing time, surface reso lution and surface quality.

Lack of integrated generative de sign/production workflow in RWC.

T T S S

Potential for rationalised differen tiation of geometries for ease in production, logistics and assembly

1.5

fig 10a,b. Diagrams by Andreani, Stefano, and Martin Bechthold in “[r]Evolving Brick:” Fabricate 2017, 182–91. https://doi.org/10.2307/j.ctt1tp3c5w.26.

fig 10c, d, e. ‘Subtractive Machining Metrics’. Study Table by Wes McGee et al. in “Processes for an Architecture of VolumeResearchgate.” Accessed September 30, 2022.

https://www.researchgate.net/publication/312804890_Processes_for_an_Architecture_of_Volume

fig. 10f. ‘Structural Efficiency of Interlocking Joints’. Technical Analysis Diagrams by A. Borhani, N. Kalantar.

“Interlocking Shell Transforming a Block of Material into a Self-Standing Structure with NoWaste.”

RESEARCH PROPOSAL Project Intent)

“To investigate robotic wire-cutting technique for agile clay as a system of quick production subtractive manufacturing solution for mass customised markets.

Precise varying cuts, exactitude angular calculations, and the geometric customisation of the modules, sets the foundation for ‘digital fabrication’ - to constraint the moulding nature of clay in order to derive complex op timised forms.

Given the uncertainty and the deformability of the material, the need for rationalised customisation and the demand for precision, the digital fabri cation system seeks a multi-functional tool.”

Re-focusing on the key problem

Narrowing the project intent to study the subtractive technique of RWC

fig 13. Robotic production with Kuka KR60, steel wire-cutter as end effector and work-holding setup (by Bingze Li)

RESEARCH PROPOSAL (Aims and Objectives)

To follow a technical pathway of digital fabrication of robotic wire cutting with the local clay through a series of experiments that tests the limits of the material behaviour, fabrication tool and computational feasibility.

1. Material Study: Studies to observe how the malleable nature of clay, its composition, moisture levels and mechanical friction with the tool impacts the productivity of the fabrication process.

2. Fabrication Study: Quantification of the robotic tooling parameters like tool speed, plane orientation, work-holding, toolpath resolution, etc to sets the limits of manufacturing tolerances.

3. Geometric Study: Parametric computational studies to define interface behaviour and geometric freedom for better degrees of customisation.

4. Toolpath Workflow: To define a subtractive motion planning workflow for robotic wire cutting clay to produce optimised stereotomic assemblies.

Project Aim Project Objectives

1.7

Statement of overall intent for the project 1.7

Practical steps carried out to achieve the research aim.

fig 14. Flowchart explaining the key intents of the RWC with respect to material, fabrication and geometry: material efficiency, production accuracy, parametric design and mass customisation (bridging craft and technology).

RESEARCH PROPOSAL (Research Question)

For a given volume of clay, how can a digital fabrication workflow be generated for subtractive manufacturing using robotic wire-cutting?

How can this digital fabrication workflow be optimised for non-object oriented goals through parametric subtractive motion tool planning?

Primary & Secondary research questions

Defining the research questions as the baseline of the project

1.8

The primary intentions of the experiments are to understand the relation ship between the material, the tool and the geometry. The given clay stock is a soft material, and the tool is a sharp one which can create deep effects, undercuts, remove volumes and varied surface area finishes.

There is a negotiation between the material stiffness and tool motion. Thus, it is an optimisation process to define the most optimum fabrication time, geometry scale, thickness, volume, edge definition, moisture for sur face quality, resolution for textures and curvatures for complexity.

fig 15. Mind-mapping the key interdependencies between material, fabrication and geometry that optimise the system for the key stakeholders of the research: RWC digital fabrication application for low-tech post-disaster contexts.

RESEARCH PROPOSAL (Research Methods)

1. understanding performance of complex interfaces in terms of geometric, material and fabrication response.

2. investigating techniques of cutting through fabrication simulation, using software integrated with an industrial robotic arm (3D modelling in McNeel Rhino, scripting in Grasshopper, robotic simulation in Robots plugin)

3. switching between digital-physical feedback – robotic fabrication, simulation (KUKA KR60) and scanning, design optimisation (Crea form Handy Scan 700)

4. developing simple, adaptable tooling and end effector system for the automated fabrication that can be translated to the craft sector tools.

5. prototyping and cataloguing models, analytic tools, and documentation as prelimi nary physical testing systems.

16. Series of steps to study the potentials of the digital fabrication process of RWC

“Assessing the potentials of digital fabrication through a robotic wire cut ting workflow for production of stereotomic ceramic assemblies.”

To develop an integrated workflow for manufacture of ceramics:

1. Manufacturing Development: Material, fabrication & geometric studies.

2. CAD-CAM Workflow: Parametric scripting for the digital-physical system.

3. Design Application: Prototyping Studies of the RWC digital fabrication.

Key Chapters of the Process

List of feedback based methods for testing the potential of digital fabrication of RWC

RESEARCH PROPOSAL (Research Plan)

Design for Manufacture Setup

Design to Production Study Plan for the Research

1.10

The research charts out a series of design investigations using the physical and the digital tool to derive the optimised design and fabrication parameters for ceramic assemblies.

The preliminary physical tests aim to explore the parameters that define a wire-cutting workflow by study ing the flexibility of this process and develop a tectonic system by actively engaging with material explo rations (Experiments).

The second step plans to incorporate these construction variables as material information into the digital parametric model (Parametric Process). Finally, in the fabrication phase, as per the specificities of the construction technique, the research seeks to test an application (Final Prototype).

Thereby the project explores an interwoven workflow based on material expression – computational complexity – fabrication information to develop a wide reaching, design flexible and a faster pace of pro duction of non-standard modules (Robotic WireCutting of Clay).

fig 17. Fabrication platform setup with the standard material parameters in place from the preliminary tests.

fig 18. Initial Robotic Fabrication Setup for feasibility studies (Manufacture Development)

fig 19. Robotic Bay Spatial Study (Fabrication Environment)

MANUFACTURE DEVELOPMENT

(Feasibility Studies)

Initial Process Experiments

more flexible tooling wire tensioning system

toolpath strategy volume envelope

surface friction geometry deformation

Quick setups, tools and stocks were used to test the feasibility of this automated process, given that the robots are versatile tools that can be integrated in the design to production process due to its flexibility in both digital and physical modes. It was important to see how it controls the material plasticity.and key obser vations were recorded.

cutting speed positive and negative geometry

clay compostion clay state post processing

Feasibility studies to identify the parameters involved in the DFM process.

2.1

fig 20. Preliminary tests with the KR6 Robot and simple setup

MANUFACTURE DEVELOPMENT (Relationships

Matrix)

MOISTURE & GROG CONTENT ADHESION LEVEL

VARIABLE MATERIALITY

RULED GEOMETRIES (FORM)

TEXTURED COMPONENTS

RATIONALISING FREEFORM

SIZE AND EXTENSION PRECISION & TOLERANCE SURFACE QUALITY CUTTING SPEED VARIABLE TOOLPATH SOFTWARE

high grog content, high green strength and low shrinkage works better. how difficult the cut part is to remove from the stock? how does the clay composition affect the stability and cut?

are ruled surfaces a limitation for the process? does discretization and local approvimation aid in cutting freeform geometries? rough milling or detailing of textures possible?

tool size restrictions wrt working volume and geometry precision in movement and volume removed at locations (conic vertices, sharp angles, etc) smoothness finish and consistency for assembly, especially stereotomy?

cutting speed and orientation for optimisation changing toolpaths for internal vs external cuts, deep/shal low cuts, etc optimisation software like PyRAPID that clusters similar toolpaths within the geometry and computes inverse kine matics.

material geometry tool process

This research tries to develop an integrated workflow for design and manufacture of ceramic modules.

Preliminary tests were carried out to understand this material response to the tooling technique – how does material removal work effectively in a single sweep rather than layers. Some key empirical relations were identified between the material and the tool.

Key observations were the intolerances and deforma tions that affect the ‘adaptability’ of this robotic auto mated system. To counter them, a series of evaluation criteria were mapped out with questions to address under key stakeholders - the material, the geometry, the tool and the process.

Stakeholders Identification

Observations Mapping to relate the material, fabrication and geometry behaviour

MANUFACTURE DEVELOPMENT

2.3

(Preliminary Tests)

Now, the first three challenges faced by the material when simple cuts and setup were acted upon the given material stock are: surface resolution, geometry deformation & material displacement

1. From the above tests, firstly, it is observed that the geometry deformations during and after the cuts are an area of concern. This is due to the surface friction between the steel wire in motion and the clay material in static mode.

2. The second key observation is material distortion during de moulding/unmoulding I.e., while separating the positive and the negative workpieces from one another. Here, the wire deflection behaviour and material composition, both affect the shape devia tion from the target geometry. The deflection length of the wire is controlled inversely with increasing speed.

3. The third key criteria are the surface smoothness and the need for post-processing of the geometry. Initially, the cutting speed and the work-holding system are defined to understand the impact of different geometries and their respective surface resolutions.

Accuracy as the key challenge

Identifying ways to tackle accuracy in terms of resolution, displacement and deformation

fig 22. Interactions between the tool and the material and the inaccuries countered.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Material Behaviour)

2.4.1

(Geometric Deformation)

01 02 03 04

The fresh state of clay (moisture 75%) produces upto 10mm tolerance changes in Z-direction using simple linear cuts. (as seen in case ) In combination with horizontal zigzag cuts along the perpendicular direction leads to 50% less in distortion within the boundary limits of 2mm to 5 mm in the perpendicular direction. However, this leads to textured finish for non-planar cuts. (as seen in case )

The green state of clay (moisture 50%) works well with linear cuts with time pauses to avoid friction build-up. This produces least distortion with minimal 2mm tolerance changes in the perpendicular direction using the simple cut itself. This combination uses least speed, minimal plane direction changes and clean finish. (as seen in case )

However, if the clay is in semi-leather hard state (moisture 25%), it is still possible to produce cuts. Here, it shall be used with vertical zig zag cuts along the parallel direction using minimum speed of 3 mm/s and multiple pauses yet leading to 1mm tolerance cuts with basic impressions. (as seen in case )

01 02 03 04

To study the material impact on the accuracy of the process

Geometric Deformation: To study the impact of toolpath variation with moisture changes of the material

2.4.1

fig 23. Geometric deformations due to toolpath motion on different clay states (fresh, fresh+, green, leather hard)

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Material Behaviour) (Material Distortion)

2.4.2

The 3DP red earthenware with shrinkage 12% in the green state shows least material displacement of 7 mm in the perpendicular direction and geometric deviation of 8mm per sq. mm of surface area.

This provides much ease in demoulding versus the 3DP stoneware with shrinkage 8.5% in the fresh state that shows maximum material displacement of 12 mm in the perpendicular direction and geometric deviation of 10mm per sq. mm of surface area

The third option that works effectively with low shrink age, high grog and optimal leather hard stage is the Vul can stoneware clay with most minimal displacements of 3mm in the parallel direction and geometric deviation of 4mm per sq. mm of surface area.

PF 3D - Red Earthenware

Firing range: 970-1055oC

Water content: 25% Drying shrinkage: 12%

To study the material impact on the accuracy of the process

Material Distortion: To study the impact of material composition on the geometric deviation.

2.4.2

PRAI 3D - StonewareClay

Firing range:1240-1300oC Water content: 22% Drying shrinkage: 8.5%

Vulcan Black Stoneware

Firing range:1200-1260oC Water content: 21% Drying shrinkage: 7%

fig 24. Testing geometric deviation for three clays of varying moisture, shrinkage and firing range.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Material Behaviour)

2.4.3

(Material Parameters)

To study the material impact on the accuracy of the process

Material type and moisture levels as evaluation criteria in the parametric script.

2.4.3

The prototypes are analysed as per the material change (three clays with different shrinkage, moisture, and grog composition) and the adhesive na ture of the clay (composition). These further help in defining fabrication solutions for every parameter within the parametric RWC workflow.

fig 25. List of material parameters that define the digital fabrication workflow.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Production Limits)

2.5.1

(Surface Resolution)

The criteria studied here is the surface smoothness and the need for post-pro cessing of the geometry. Initially, the cutting speed and the work-holding system are defined to understand the impact of different geometries and their respective surface resolutions.

With the optimal parameters from the previous tests, four sets of basic ge ometries from a planar cut to doubly curved geometries are cut, to study the surface finish. It was observed that the surface resolutions of the contin uously changing surfaces were the most optimum due to control on friction, change in planar angles and edge behaviour interactions.

Special characteristic of this system is the generation of only ‘ruled’ surface geometries. This informs the influence of geometry on material behaviour.

To study the impact of fabrication precision on the geometry

Surface Resolution: Impact of tool movement on the surface smoothness 2.5.1

fig 26. Achieving optimum material surface resolution by establishing standards in material-fabrication setup.

MANUFACTURE DEVELOPMENT

2.5

2.5.2

(Key Optimisation Parameter: Production Limits) (Geometric Taxonomy at Surface Level)

The digital fabrication process is a workflow between the design and the toolpath. The algorithm was developed on Grasshopper that has the flexibility to manage a range of parameters for flexible customisation. This geometric logic is transferred to the KR60 robot automated fabrication system. The plugin Robots was used to generate, simulate, analyse, and optimise motion paths.

This is done by defining the target planes and tool centre plane by taking their position and orientation in real time and translating them into robot code. The toolpaths or the robotic trajectory is then defined by the required sorting and alignment of the planes in order. Similarly, the machine code which acts as guiding lines is generated for varying geometries. However, to make this process more effective, it is important to consider the parameters of the automated system as well, like the collision of wire cutter and stock needs to be avoided by limiting the rotating angles along the cutting path, and the digital tool helps to compute this with inverse kinematics.

The lead-in and lead-out movements also define the geometry distortion and dis placement at right locations. Also, multiple rotation in planes also impacts the precision to the cut. To avoid this, the plane and zone parameters are modified. Hence system customisation.

To study the impact of fabrication precision on the geometry

Tool Behaviour and Customisation Impact on the surface geometry

2.5.2

fig 27 Customisation of the toolpaths as per material form, rotating angles and curvature.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Production Limits)

2.5.3

(Geometric Taxonomy at Form Level)

As studied, the key inputs for the setup that inform the geometry of the module are the path curves, their relative points, and the target planes which relate to the fabrication limits. Thus, there is relationship between their design and target geometry. Moreover, the simulation as well antici pates this workflow relationship.

Therefore, to optimise the process, the geometry can be modulated in ac cordance with fabrication constraints. One needs to study the adaptability of the physical tooling to understand the geometric limits exploration. The material parameters are kept constant now, like the material moisture, stock volume and cut surface area.

To study the impact of fabrication precision on the geometry

Geometric Modulations in accordance to the fabrication constraints

2.5.3

fig 28. Relationships between geometric accuracy and fabrication parameters of the robotic platform.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Production Limits) (Fabrication Parameters)

2.5.4

To study the impact of fabrication precision on the geometry

Robotic parameters as evaluation criteria in the parametric script.

2.5.4

A range of parameters, like, toolpath speed, plane orientation, work-hold ing strategy, approximation tolerance zone, resolution, etc were varied one after another to achieve a prototype of minimal geometric deformations and maximum accuracy. These were then categorised in the workflow.

fig 29. List of robotic parameters that define the digital fabrication workflow.

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Geometric Customisation)

2.6.1

(Geometric Variations)

Sets of geometric tests with given stock volume are studied with the following aims:

1. The depth domain within the stock for tool can reach with sharp cuts with minimal drag.

2. The slope length limits before the geometry deforms upon demoulding.

3. The optimum surface area – interface expanse to avoid adhesion while demoulding.

4. The maximum achievable volume within boundaries without geometric distortion.

5. The angular domain of the volume to study shear, tension, compression for interlocking.

6. Tool, material, and geometry behaviour with shift in angles, slopes, areas, and volumes.

To study the geometric limits that define process feasibility

Geometric Studies for optimum material usage, form stability and robot flexibility 2.6.1

fig 30. Design ideas to define the geometric limits in response to the tool

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Geometric Customisation)

2.6.2

(Production - feedback experiments)

It was observed that given a stock volume V and an objective to carve out volume v, to achieve a near net volume of at least 90% accuracy, the depth of the cut must be atleast 0.5 to 0.6 fraction of the overall depth. Other aspect that can bring in better accuracy is the toolpath sequencing which will limit the drag affecting the geometric edges and corners.

For ensuring optimal surface quality, it is noted that the surface expanse area depends on the orientation along or against the stock. The orientation angle above 45o from the +Z direction along the stock and an orientation angle above 90o from the -Z direction against the stock defines clean cuts up to expanses of 0.75 fraction of the total stock length. The control over the robotic tool speed and wait time can aid in achieving steep and larger surface areas.

Similarly, the slope lengths majorly depend on the wire tensioning. Since this is an arbitrary parameter, in terms of the tool behaviour, it is relative to the tool trajectory. The count of the target planes and their relative position density is directly proportional to the slope length. However, the slope length also impacts the edge cor ners of the cuts. Its’ precision depends on the stock load (material parameter) and the approximation zone (robotic parameter)

To study the geometric limits that define process feasibility fig 31a. Defining geometric limits and domains in relation to the tool and material behaviour

Testing these geometric variations to improve tool productivity and accuracy. 2.6.2

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Geometric Customisation)

2.6.3

(Production - feedback experiments)

Geometry volume, is a qualitative factor rather than a quantitative one. Its position within the bounding box of the stock defines the ease in tool movement within the stock, ideally from the periphery at an offset of 5mm or 5 to 10% of the stock. On the other hand, multiple passes of the robotic toolpath shall help in bulk stock re moval and achieving deep, undercut, & sharp relief volumes.

The studies on the angular domain did not produce clear results due to, one, deformations because of the stock lengths and multi ple planar re-orientations within every 0.05 fraction of the overall surface cut, two, domino effect of material distortion of one mi cro-cut to another builds up exponentially, and three, lack of live feedback between the material and the toolpath which adds up the deformations without clarity on individual angular variations.

To study the geometric limits that define process feasibility

Testing these geometric variations to improve tool productivity and accuracy.

2.6.3

fig 31b. Defining geometric limits and domains in relation to the tool and material behaviour

MANUFACTURE DEVELOPMENT

(Key Optimisation Parameter: Geometric Customisation)

2.6.4

(Geometric Parameters)

To study the geometric limits that define process feasibility

Geometric parameters as evaluation criteria in the parametric script.

2.6.4

Till now, the material and fabrication parameters aided in a strategic RWC with minimal material distortion, minimal geometric deformations, and maximum surface resolution. To further adapt this system and setup com putational parameters for design applications, a series of geometric tests are done at varying scales within the fabrication framework (robotic and material envelope). These parameters are derived for optimised RWC.

fig 32. List of geometric parameters that define the digital fabrication workflow.

MANUFACTURE DEVELOPMENT

2.7

(Digital Physical Feedback)

The key intents are the control of material distortion, geometric defor mations, and surface resolution, while a series of sub-intents are to de fine the fabrication parameters like production time (for high volume and low-cost production), material optimisation (managing stock-ge ometry ratio and work-holding), manufacturing quality (production pre cision and tool health control).

Key Parameter Selection

Checking of tolerances and accuracy through feedback looping.

fig 33. Data feedback loop: Wire-cutting, Kiln firing, Scanning Tolerance, Interface Checks

fig 34. Key parameters for production accuracy in RWC

fig 35a. Stock manufacture process with clamped framework and ramming, using local available clay.

fig 35b. Robotic tool end effector setup (wire-cutter loading and calibration setup on the digital interface.

fig 35c. Digital simulation and toolpath development using integrated design to fabrication softwares. fig 35d. Physical robotic fabrication following the parametric defined G-code to achieve the target geometry.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT (Strategic Toolpath Adaptation)

This graphic provides information on geometric limits and domains of an gles, slopes, lengths, areas, volumes in relation to a given material stock and in response to the tool behaviour. The conclusions from these limits shall provide feedback into the digital and physical fabrication parameters.

Given a particular geometry, how can this robotic wire cutting be optimised with a list of techniques? Learning from the conclusions, different logical sequences of toolpaths are developed in accordance with the geometries.

These strategic toolpath adaptations constituting the material, fabrica tion and geometric parameters help in charting out well-defined robotic wire-cutting manufacturing pathway for clay/ceramic materials. This fur ther leads to understanding the role of wire cutting workflow for clay in relation to the workflows of other subtractive systems of manufacturing.

Toolpath Planning for RWC

Deriving toolpaths as per the design need with embedded parameters.

fig 36. Variation between the digital model, simulation model and the physical model to derive toolpaths

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.1 (Strategic Toolpath Adaptation)

3.1.1 (Material Distortion)

Derivation of a CAD-CAM Workflow for RWC

Key Design need here is minimum material distortion

3.1.1

It is seen that at the edges, distortions lead to cur vatures, and these are directly related to the slope angles at those junctions. For less tolerances here, it is advisable to have sweep horizontal cuts at higher speeds, followed by vertical zigzag cuts in parallel offset to the edge to lower the friction as it goes closer to the target cut.

Finally, the target cut can be managed with min imal speed, suitable wait-time relative to each plane and re-orientation of neighbouring tool planes to their normals. Finally, the target cut can be managed with minimal speed, suitable waittime relative to each plane and re-orientation of neighbouring tool planes to their normals.

fig 37a. Toolpath derivation for minimum material distortion

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.1 (Strategic Toolpath Adaptation)

3.1.2 (Geometric Deformation)

In another instance, for less deformations in deeper vol umes and steeper slope angles, a roughing toolpath type of strategy is employed. Here, multiple passes with equal or incremental offsets are carried out to remove the bulk material from the stock and slowly inch towards the fine target geometry. For this strategy, the depth and the width of the volume are considered and are proportional to the toolpath offset distance.

For volumes where the depth is almost equivalent to the width, it implies steeper slopes, higher target plane den sity, and therefore for optimal cuts, the offset distance decreases leading to multiple passes with almost equal offset distances. Whereas for volumes with variation in depth versus width, there needs to be balance between removing maximum bulk versus minimum production time. Here, the offset distance increases with minimal passes and incremental offset distances.

Derivation of a CAD-CAM Workflow for RWC

Key Design need here is minimum geometric deformation.

3.1.2

fig 37b. Toolpath derivation for minimum geometric deformation.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.1 (Strategic Toolpath Adaptation)

3.1.3 (Surface Resolution)

In the third instance, where in, the surface resolution and smoothness are of prime concern due to large sur face area expanses, the lead-in and lead-out define the trajectory of the cuts. This is negotiated by studying the relationship between the surface area and lead-in tool path offset distances; as well as the relationship between the expanse length and lead-out toolpath slope angle.

The lead-in toolpaths ideally run in parallel to expanse lengths with calculated offset distances as the consisten cy in friction needs to be maintained while the lead-out toolpaths are quick and sharp as it must remove material bulk effectively so that the adhesion does not disrupt the remaining fine material closer to the near net shape.

Derivation of a CAD-CAM Workflow for RWC

Key Design need here is maximum surface resolution. 3.1.3

fig 37c. Toolpath derivation for maximum surface resolution.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

(Toolpath Methodology)

This research seeks to hybrid both these systems and adapt wire-cut ting to clay behaviour. Since it’s adhesive character challenges the demoulding post-cutting, experiments to mitigate the inaccuracies, involve both roughing and fine toolpath strategies. This optimises the cutting sequences of wire cutting and deems it an efficient prototyp ing iteration system for plastic materials like clay.

To make this digital fabrication system more efficient, adaptable, and versatile, the following is an attempt to make it a logical, procedural based parametric workflow which is adaptable to a given material composition, fabrication limits and geometric customisation. This is termed as subtractive motion planning for RWC.

For given stock volume, identify the target geometry volume, depth, slope lengths, surface areas and angles. Compare these in propor tions to the above limits in the parameters table:

Methodology Example

The key logical steps for optimal cuts through RWC for a given geometry

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

(Toolpath Methodology)

Study the volumetric nature of the geometry. If the ratio of target volume and the stock volume is almost equal to 0.50; target height to stock height is more than 0.50; and residual height is equal to 3/4 overall height; these define the relative position of the target geometry within the stock. Hence, it is observed that it needs around 4 number of roughing cuts parallel to the max. Z height of the target. It is advised to run at max. speed of 8mm/s and tool planes can be continuous in parallel direction for faster, rough cuts.

While studying the volume height and steepness of the slopes, here the height is almost equal to the length of the volume, and therefore, the geometry requires minimal passes with incremen tal toolpath offsets. These offsets are proportional to the volume height, and it’s offset distance should be around 1/3 times the height. In this case, the speed of the offset cuts is decremental as close to the target geometry to ensure minimal distortion. The change in curvature of the cuts is proportional to the slope angle. This is done to remove the bulk material smoothly.

Methodology Example

The key logical steps for optimal cuts through RWC for a given geometry

fig 39. Toolpath methodology for a given geometry

SUBTRACTIVE MOTION TOOLPATH

(Toolpath Methodology)

DEVELOPMENT

Now, for the fine toolpaths, a zigzag toolpath motion normal to the planes and about 3mm offset from target periphery sets an easy frictional rough base for the final cut. Here, the toolpath res olution is key, the plane count is relative to the angle domain above 180o and hence should be 18. The plane positions are relevant for ease in plane re-orientation. Their location is dependent on the slope length and the toolpath offsets. They are denser at the discontinuous points of the cutting profile for min. tolerances at edges.

For the final cut, the three criteria are the most critical – minimal material distortion, minimal geometric deformation, and maximum surface resolution. Hence, the speed control should be 5mm/s at the dense planes with a wait time of 2 seconds at all planes. Another robotic parameter to be checked is the approximation zone to be zero. The last aspect is the re-orientation of the planes parallel or perpendicular to the cutting profile as per the slope angle. These key steps help in optimising the fabrication sequence and developing a quality manufactured prototype.

Methodology Example

The key logical steps for optimal cuts through RWC for a given geometry

fig 40. Application of toolpath methodology to physical fabrication

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.1 (Logic Diagram)

INPUT GEOMETRY

Workflow PseudoCode

The key logical steps for the parametric workflow from geometry to toolpaths

3.3.1

OUTPUT TOOLPATHS

fig 41. Workflow - Logic Diagram from user defined INPUT geometry to program generated OUTPUT toolpaths.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.2 (Fabrication Setup)

Robotic Setup

0.

0. INPUT

1. Select the Robot Type

2. Extraction of Payload Data 3. Defines the wire-cutter (end effector) design.

4. Results Wire-cutter dimensions.

5. OUTPUT

INPUT

1. Select work-holding geometry 2. Base Points Calibration

3. Defines the stock location.

4. Results Stock Volume extents.

5. OUTPUT

Work-holding Setup

Fabrication Setup

Overall robotic fabrication setup comprising tool, workholding and stock.

3.3.2

After inputting the target geometry, the users can select the robotic platform that determines the relevent end-effector (tool), work-holding needs, efficient stock volumes, calibration data, etc - all this embedded as a program from the outcomes of the manufacturing experiments.

fig 42. Fabrication setup pertaining to the robotic limits.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.3 (Design Parameters)

01 02 03 04

01. The wire cutter dimensions determines stock size extents. 02. The workholding geometry defines the stock volume limits. 03. The target geometry informs the bounding stock to cut. 04. Bounding stock sizes provide the stock geometry needed.

Design Parameters - Stock Setup 3.3.3

Determination of the stock geometry from the fabrication setup.

fig 43. Stock setup - how the tooling boundaries (Robot) relate to the material limits (stock of clay) and its response.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.4 (Evaluation Criteria)

M

F F

Material parameters

Fabrication parameters

Geometry parameters

For every geometry, once the user defines the design need, the material, the geometry and robot, the program automically generates toolpaths through these in-built parameter framework. These are adapted systems learnt from the manufacture development tests.

M G G

Evaluation Criteria - Key parameters 3.3.4

Selection of criteria for toolpath customisation based on previous observations

fig 44. Tabulation of the material, robotic and geometric parameters as an evaluation criteria.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.4 3.3.4.1 (Production Data) (Material Distortion)

Design Need Surface Toolpath Generation

Design Need: Material Distortion fig

Series of roughing and finishing toolpaths with the defined criteria. 3.3.4.1

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.4 3.3.4.1 (Production Data) (Material Distortion)

Design Toolpath

Design Need: Material Distortion

Series of roughing and finishing toolpaths with the defined criteria. 3.3.4.1

fig 46. Phygital toolpath generation platform for the RWC design need: Minimise Material Distortion

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.4 3.3.4.2 (Production Data) (Geometric Deformation)

Design Need: Geometric Deformation

Series of roughing and finishing toolpaths with the defined criteria. 3.3.4.2

Design Need Surface

fig 47. Phygital toolpath generation platform for the RWC design need: Minimise Geometric Deformation

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.4 3.3.4.2

(Production

Design Toolpath

Data) (Geometric Deformation) fig 48. Phygital toolpath generation platform for the RWC design need: Minimise Geometric Deformation

Design Need: Geometric Deformation

Series of roughing and finishing toolpaths with the defined criteria.

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

SUBTRACTIVE MOTION TOOLPATH DEVELOPMENT

3.3 (CAD-CAM Workflow)

3.3.5 (Digital Physical Process)

Parametric Design Process

Showcasing the overal design to production workflow for applications.

3.3.5

The next step: How can this digital fabrication method be applied for the manufacture of interlocking ceramic bricks in a stereotomic context with the need for accurate interfaces for structural stability?

The above physical and digital tests help manage fabrication tolerances. These strict tolerances are required for stereoto mic assemblies. The accuracy at the interface cuts helps the modules self-support in assembly.

fig 50. Feedback Loop of user-automation and digital-physical in the CAD-CAM Workflow for RWC

fig 51. Work-holding platform (Bingze Li) for stock volume determination in response to target geometry

fig 52. Design explorations as an outcome of the CAD-CAM Workflow

4.1

DESIGN APPLICATION: PROTOTYPE (Contextual Research)

The design brief investigates the tectonic achievements of architec tural ceramics in traditional contexts, here, the structural potential in the vernacular construction of Bhunga houses in the seismic local ity of Kutch, Gujarat, India.

This low-tech clay-rich economic context has efficient seismic resis tant structural systems – the circular global geometry of the Bhun gas whose inertia forces are resisted through shell action providing excellent resistance to lateral forces, low walls for stability and, thick walls as thermal walls and high plane stiffness.

Tapping on these resources and learning from the seismic resistant local Bhunga forms, the context demands structures that can be pro duced quickly for emergency rehabilitation, which can be assembled with ease and speed using low-tech available resources, constructed without any scaffolds, and can be locally produced at a faster rate.

Context Brief (Architectural Ceramics)

Examination the needs of the design brief for a given context. 4.1

fig 53. Research Studies by Priya Shah, “Ludiya: Partnering with People an Effort in Redevelopment with Community Participation.” Community Redevelopment | Ludiya.

‘Seismic resilient craft constructs’. Drawings by the Environment Design Team : Vastu-Shilpa

fig 54. Defining the role of craft and technology in the application of the RWC research at Kutch, India

DESIGN APPLICATION: PROTOTYPE

(Module Design)

The project attempts to relate to the context and rethinks a macro-struc ture as a structurally performative response to the unreinforced Bhunga masonry forms. With the focus on robotic stereotomy, this can be achieved through self-supporting structures with interlocking modules. They are monolithic construction where the position of modules and their joints are the driving structural forces without the need for mortars or connectors.

Stereotomic Modular Design

Geometry design and fabrication testing using RWC parameters.

The geometry was designed within the limits of the given volume of stock and the target geom etry was 25% of the stock. Key elements are slope angles which were in the range of 45o to 125o for ease in plane re-orientations and setting up lead-in and lead-out trajectories. The module is achieved in 10 minutes production time with 8 roughing and 6 finishing toolpath passes. The rest of the parameters are enlisted in the table. On digital scanning and overlay, it is studied that the geometric accuracy is 85%. The issues faced were at the inclined edges and interface locations.

fig 55a & 55b. Module design and definition of the geometric parameters for RWC and toolpath development

DESIGN APPLICATION: PROTOTYPE

(Aggregation Design)

From the conclusions of design and fabrication of 1D modules, the assembly investigates 2D and 2.5D module aggregations try ing to seek balance, on one hand, the assembly behaviour due to its orientation, porosity, and direction, and on the other hand, the efficiency of fabrication. Beyond this, the 3D assembly aggrega tions were developed for longitudinal, transverse, and diagonal growth systems development.

Moreover, the interface is important for the stress distribution and static equilibrium in the structure. This research intends to study a novel tectonic within this geometry of the interface. Through tests with series of planar and non-planar edge faces, it is strategic to observe how the ruled interfaces resist each other through counter forces and avoid failure.

Assembly Design Process

Different permutations and combinations are studied as per the geometric interlocking behaviour.

fig 56. Module assembly logic with digital fabrication and application perspective

DESIGN APPLICATION: PROTOTYPE

4.4 (Interface Studies)

As they stagger and cantilever, how does the moment force that shifts the module out of place is counter acted by the shear forces of the ruled geometry? How is the module interlocked and what is the impact of their self-weight on supporting each other? The detailing of the module requires understanding of the joint geometry as well. Studies show that three-dimensional joints can resist shear, torsion, and compres sive forces. Can variation of planarity and curvature across the interfaces aid in efficient interlocking?

The interface studies were done from planar semi-circular curves to doubly curved hyperbolics. On dry ing, it was observed that for a given stock volume of 120mm x 120mm x 120mm; the geometries with curvature until 0.2 mm-1 showed the least tolerance of about 2mm to 5mm. These included semi-circu lar cuts under both single and doubly curved category and hyperbolic curves under the non-planar ones. Upon scanning and checking shrinkage post firing, the gradual curves of hyperbolic paraboloid interfac es show minimum assembly issues due to uniform shrinkage along and away from the curved profile.

Interface Geometry Tests

Overlay of physical testing and digital scanning to understand behaviour.

fig 57. Interface tests with scan overlay to observe shrinkage, deformation

fig 58. ‘Interface: Structural Analysis.’ Studies by D. Reinhardt, Weir, S. and Fernando, S. (2017, November 1).

https://www.academia.edu/34883840/Simulating_Self_Supporting_Structures

DESIGN APPLICATION: PROTOTYPE

4.5 (Design Development)

Interlocking assemblies development

Design development with the RWC fabrication constraints incorporated. 4.5

The assemblies were incorporated with the hyperbolic paraboloid at the inter face and one of the 2.5D aggregation is selected. A subtractive motion plan ning flowchart is developed to sequence every cut by evaluating the material, fabrication, and computational parameters. This exercise is evaluated based on geometric deformations, material distortions and surface tolerances.

fig 59a. Exploded module design

fig 59b. Hyperbolic Paraboloid Interfaces in module geometry for RWC

DESIGN APPLICATION: PROTOTYPE

(Fabrication Tests)

Physical fabrication outcomes: The material moisture level in combination with the toolpath speed and zig-zag motion definition aids in achieving 90% accuracy while assessing material distortion. Comparing with the parameters chart of the geometric limits, the angular domain of 90o to 120o helps in smooth lead-in, target, and leadout plane alignment within a maximum movement range of 3mm/s to 8mm/s which avoids deformations especially at edges and corners.

Workflow fig 60. Assembly setup and individual target geometry fig 61. RWC Fabrication for cut-volume module

Digital-Physical

RWC Fabrication as per the methodology developed

DESIGN APPLICATION: PROTOTYPE

Structure

Design

Module & Assembly

Parametric Definition Interface Design

Contextual Design Process

Parametric design of module and assembly for RWC digital fabrication 4.7

62a to d: Design process diagrams for the Bhunga context and output as target geometry for fabrication

For the given context of Bhunga houses in Kutch, India, the individual module design and assembly is parametrically designed in relation to the overall form of the tradition al structure. The modules are further designed and assembled with the stereotomy and the structural geometry lessons learnt from the state of the art (interface design)

DESIGN APPLICATION: PROTOTYPE

Using the CAD-CAM workflow, 6 modules from the overall designed assembly of Bhu nga application were selected and fabricated with varying interface cuts. These inter faces were different angles of hyperbolic paraboloid to study structural and accuracy differences amongst the fabricated modules of the assembly.

fig 64a. Assembly of four modules of the setup showcasing the inaccuracies and behavioural impacts.

fig 64b. Assembly outcome as a tradeoff between material accuracy and fabrication optimisation.

5.1

REFLECTION & NEXT STEPS (Addressing the

research)

The simple tools of wire cutting are automated to create a quick production system for high volume-mass customisation of ceramic geometries. The re search attempted to assess the potential of this system which involved ex panding on the flexibility of the robotic tool, the complexity of the geometry and the control on the material behaviour.

Geometric adaptation in response to the limits and constraints of the ma terial, and fabrication parameters in the context of architectural ceramics encapsulates the design for manufacture workflow exploration.

Subtractive Motion Planning Workflow - Parametric Platform

For a given volume of clay, how can a digital fabrication workflow be gener ated for subtractive manufacturing using robotic wire-cutting?

5.1

The research further seeks to evaluate the non-object-oriented values of the digi tal-physical workflow. It establishes value proposition through contextualisation of architectural ceramics by resourcing local clay construction in in a low-tech econ omy, rural India. It then establishes its utilisation in the context by reinforcing the structural performance of traditional houses through the production of stereoto mic modules via the robotic wire cutting process.

Application for quick, high volume, mass customisation production

How can this digital fabrication workflow be optimised for non-object oriented goals through parametric subtractive motion tool planning?

5.1

fig 65. Changing toolpath motion trajectory across the cutting interface

fig 66. Digital overlay over physical outcome to understand the tolerance variations.

REFLECTION & NEXT STEPS

(Research Impact)

The challenge that this digital fabrication process faces is to seek ‘adapt able’ value of the workflow in terms of the context needs, the integration of this customised potential of technology with craft. The application of these studies is envisaged within local craftsmen communities, where-in their tac it knowledge can be complemented with technological innovations.

Can this digital fabrication system be used with traditional craft tools, for instance, using AR driven technology, the toolpaths (flexible multi-axis) of the robotic wire cutter can be translated for the craftsmen to follow and derive non-conventional customised geometries. Alternatively, a hand-held wire-cutting tool can be developed with the embedded programming meth odology for human users to develop tacit and personalised prototypes.

The project can propose a techno-social integration in the context with the idea of ‘industrialised craft’ in the production cycle. It can involve social assessments of the contexts and an evaluation of the benefit of the process by seeking its integral position in the manufacturing indus try, for example, development of a bespoke mass-customised market for this manufacturing process.

Non-Object Oriented Goals

Value generation within the tool or manufacturing process.

5.2

fig 67. “Augmenting Craft with Mixed Reality: A Case Study Project of Ar ...”.

https://www.researchgate.net/publication/355668377_Augmenting_Craft_with_Mixed_Reality_A_Case_Study_

Project_of_AR-driven_Analogue_Clay_Modelling.

Object-oriented goals

Value generation in the form of a product or production output.

5.2

fig 68. Nanayakkara, Suranga. “The Hybrid Artisans: A Case Study in Smart Tools.” MIT Media Lab. https://www.media.mit.edu/publications/the-hybrid-artisans-a-case-study-in-smart-tools/.

fig 69. Andreani, Stefano, and Martin Bechthold. “[r]Evolving Brick:” Fabricate 2014, 2017, 182–91. https://doi.org/10.2307/j.ctt1tp3c5w.26.

REFLECTION & NEXT STEPS

5.3 (Research - Future Steps)

With the development of digital analytical tooling and ability to detect tolerances, the process effectively allows control both the material behaviour and geometric exploration. An additional lay er of optimisation can aim for performative goals with economical manufacturing system of customised modules. The open frame work platform of robotics and the feedback loop intensifies its capabilities and extends its limits towards bespoke design appli cations for environmental or structural goals.

RWC can further be improvised or adapted with other manufac turing techniques to extend its geometric capabilities as well, for instance, to allow more sectional or internal voids, incremental modular forms with microvariation/edge conditions, or produce the most efficient cut per unit cost of tooling, or to necessitate minimum stockholding or production of varying thicknesses as per the material state change or so on, for varied applications.

On the technical front, the process has the feasibility to further explore the limits of the multi-axis. Its adaptive nature in terms of motion trajectory and toolpath development works in symbiosis with the material response. There are applications that can be explored for robotic toolpath sequence optimisation like PyRAPID that clusters all the cuts into a single sweeping motion and com putes the toolpath movement by optimising the robot reachabil ity. Further, the end tool can be actuated for realtime feedback.

Future Steps for the research

How could/will the research continue?

P process

structure S

PERFORMATIVE DESIGN NON-CONVEN TIONAL GEOMETRY WIRE-CUTTING CERAMICS

T tool

5.3

fig 70a. Andreani, Stefano, and Martin Bechthold. “[r]Evolving Brick:” Fabricate 2014, 2017, 182–91. https://doi.org/10.2307/j.ctt1tp3c5w.26.

fig 71a. Digital simulation of non-ruled surface geometry by Harsh Manish Shah, Bartlett School of Architecture, UCL, London.

fig 70b and 72b. Rossi, Gabriella, James Walker, Asbjørn Søndergaard, Isak Worre Foged, Anke Pasold, and Jacob Hilmer. 2021. “Oscillating Wire Cutting and Robotic Assembly of Bespoke Acoustic Tile Systems.” Construction Robotics 5 (1): 63–72. https://doi.org/10.1007/s41693-020-00051-8.

fig 72c. Loh, Paul, Yuhan Hou, Chun Tung Tse, Jiaqi Mo, and David Leggett. “Freeform Volumetric Fabrication Using Actuated Robotic Hot Wire Cutter.” SpringerLink. Springer Singapore, January 1, 1970. https://link.springer.com/chapter/10.1007/978-981-33-4400-6_26.

fig 71c. “Min-Max: Reusable 3D Printed Formwork for Thin-Shell Concrete ...” https://www.researchgate.net/publication/361124576_Min-Max_Reusable_3D_printed_formwork_for_thin-shell_ concrete_structures_-_Reusable_3D_printed_formwork_for_thin-shell_concrete_structures.

fig 72a. “Processes for an Architecture of Volume - Researchgate.” https://www.researchgate.net/publication/312804890_Processes_for_an_Architecture_of_Volume.

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