Improving the Process

To get rid of the flat inner surfaces of the bricks causing us problems, several different versions of creased surfaces were experimented with and evaluated. We finally settled for a variant involving wavy transformations of the straight surfaces in three different directions. By using an undulating plane to cut away from the flat surface, all of the flat inner sides of the bricks could be transformed into wavy ones, and thus, for the second column we were able to produce increasingly consistent bricks.

Furthermore we decided to have each layer of the structure to be comprised of only two bricks in the production of the second column, and make the bricks twice as large. Fewer but bigger bricks increase efficiency when 3D printing.

To the left, the iterative process behind the development of the wavy backside is shown, and below, the final version, used in all three consecutive prototypes following the first column, can be seen. We still had some problems with defomations in the second column, but that was probably mostly due to the bold overhangs created by the noise. In the arch and the weave, however, we experienced very little problems of deformation.