ExLaB
Allie_Jingyi_Liu 911702 FINAL Design Journal NOV_20_2023
exlab.org
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Contents 0.0 Introduction 0.1 Ethos 0.2 FabLab Access
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1.0 Joint Demo - Puzzle Cube 2.0 Stool 01 - Omnivore Stool
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3.0 Stool 02 - For Lack of a Better Name Stool
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4.0 Technoblade Stool
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Introduction
Omnivore Stool, Jingyi Liu & Tan, 2023
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The Experimental Design Lab, or ExLaB, is a design laboratoryat the UniversityofMelbourne, that explores, researches and creates design through an experimental process focused on the materials and machines things are made from. Playful experimentation and prototyping remain at the core of the ExLab pedagogy. Designers are encouraged to interrogate and challenge the use of common materials through processes of testing, iterating and making. Students are encouraged to investigate and exploit the strengths, limitations and peculiarities of both traditional and contemporary materials and machines. This edition of ExLab incorporates the use of contemporary data capture and additive manufacturing technologies to help students inform their research and design approach.
Omnivore Stool, Jingyi Allie Liu & Tan, 2023, Prototyping
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This subject challenges students to design a piece of furniture using an experimental design process that is driven by material qualities using contemporary processes of making.
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FabLab Access Students will have access to operate and/or supervise machinery in the FabLab if appropriate safety inductions have been completed. There are 3 levels of safety induction in the FabLab. (Visit Training Centre Website for more info) lv 01 - General FabLab Safety Induction General introduction to workshop safety principles and procedures assessed via online multiple choice assessment. Assessment must be completed to gain access to any space in Fabrication Workshop. lv 02 - Machine Workshop Safety induction In person familiarization and introduction to the machine workshop and technical staff. An induction session will be arranged for all ExLaB students during class time. This must be completed for students to gain access to any equipment beyond G12, the Forbo Model Making Space. lv 03 - Specific Machine training and certification In person training on specific workshop machinery. Refresher is training required each semester. If students wish to use any machinery in the Machine Workshop this certification must be completed.
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1.0 Object_Puzzle_Cube
Puzzle Cube, Jingyi Liu & Tan, 2023
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Design References & Research
As the first task into creating an object that explores joints and connections employing 3D printing Techniques, we were intrigued to maximise the free-form sculptural/stereotomical nature encapsulated by Additive Manufacturing Processes. An Additive
Manufactured
Object,
being
the
opposite
but
interchangable to a cut-stone object, is characterised by the corresponndence between form and structure1. In such senario, connection joints and form can be the one and same thing. Inspired by Oyler Wu Studio’s furniture and puzzle pieces, our initial exploration were based on joint-driven-sculptural-form, and the concept of wholeness and its relationship to parts.
(1)
(2)
(1) Jacob Levy, Puzzle Object Assembles (Taught by Dwayne Oyler) An exploration of interlocking parts and its formed boundary (2) Dwayne Oyler, Puzzle Assembly Series A system of curiously interconnected parts that form a unified whole.
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1
https://www.arct.cam.ac.uk/system/files/documents/vol-1-951-968-defilippis.pdf
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1.1
Formal Intent
A cube in the dimension of 150x150x150 is anchored by a series of rotational, interlocking and sliding joints and divided into multiple sculptural objects each with their own characterestics, making it an complex of objects that is consciously kept as a cube but not quite a (1)
(2)
(3)
cube, a quasi-cube. The Puzzle cube object is used to test out different kinds of connection types that can be printed in place with minimal Supportings in a FDM 3D printer. Initiated by locating suitable joints through blocking, sketching and
(4)
(5)
(6)
manually visualising in Rhino, the shape of each objects and its seams to adjacent parts were derived by individual parts’ mass and movement. For example, a straight line on the exterior indicates sliding motion and a curved line often indicates a rotational movement. The entire cube were kept as purely 3D printed, intending to kept this task as a pure formal exploration and imbeds as much joints as possible before the deadline of week2’s session, due to this limited
(7)
(8)
(9)
(1) Cube in its platonic form, (2-3) Morphing of form subjected to rotational joint movement, (4-6) Playful interlocking of joint curiosities, (7-9) Dismentaling of platonic form and the formal value of parts
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time frame, the end result has turned out to be a bit anticlimatic where a certain part has been carefully saught out but the rest did not manage to match a similar complexity.
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1.2
Design Process
(1)
(2)
(3)
(4)
(5)
(1) Initial Joint & other allocations, (2) Seams & Holes derived from rotational motion, (3) Cleaning, (4) Rationalising Joints, (5) Loose Sketches for composition of devided parts.
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Puzzle Manuals
(1) Puzzle Manuals (Drawing Credit: Tan Quanchareonsap)
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Fabricating Process Due to the jointed totality nature of this cube, the assembled parts is possible to be printed in place with carful adjustment of clearances between each part. During pre-prosessing of print, a clearance of 0.2-0.4 mm of gap is produced to allow seperation between parts post printing. Each gap is determined by the surface
(1)
(4)
(5)
angle (with a wider gap for horizontal surfaces, narrower for vertical), this maunal adjustment of clearance resulted to be mostly successful but with a few failures, where smaller details tends to fuse together and large horizontal surfaces tends to produce uneven finishes. A secondary PVA/PLA mix support material is applied manually to
(2)
(3)
(6)
(7)
(1) Making Clearance inside Rhino, (2) Multipart cube printed in place, (3) PVA mix PLA material for easier break of support(4-5) Desperately seperating the cube with failure - Helper Credit:Olivia and Ed from NextLab, (6) Failed Print-in-place Joint being force-seperated, (7) Uneven surface finish due to clearance too big
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provide more successful print on the hollow overhangs, allowing better finishes.
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2.0 Omnivore Stool
Omnivore Stool (AKA. DONOUT Stool), Jingyi Allie Liu & Tan Quanchareonsap, 2023
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Design References & Research As a continnuation of the object study, we decided to further investigate the massness of stereotomic form in accordance to 3D printing. Two precidents has become influential to our study which both of them has presented a dialectical relationship between conventional tectonic stuctures and a stereotomic counterpart, either being closely merged but contrasted in materiality or hinting a brutal collage devided by a loose axis. The architectural work of Smiljan Radic aligned with our ethos, where he works within the relationships of
(1)
(2)
opposition, looking for something quite difference from a mere balance between two co-existing pairs of opposites and does not seek reconciliation which utimately have a sterilising effect.
(3)
(1) Oyler Wu studio, Jack and Jill puzzle chairs An exploration of interlocking parts and its formed boundary (2) Thom Mayne, Nee Chair The tensional association between Sterotomic and Tectonic Forms (3-4) Smiljan Radic, Study Model for Serpentine Pavilion The game of opposite Assignment_05_More_Joints_and_Connections
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Design Process
Custom: Omnivore Plinth Timber Panel: Bricolaged from Fablab
Following the previous line of thought, the stool’s primary form
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is decided to be a (Dis)junction of Customisable Stereotomic 3D Prints and a standard Stool made from avaliable resources V-Slot Aluminium Profiles $7.68 for each 1000mm
, either purchased locally or ad-hoc with pieces found from Fablab material archive. While the stool is determined to serve its primary function, its attaching plinth serves as an extension of auxiliary playful functions such as a abstract back support or a lecture table, in this case this is a stool that wanna be a chair, or something more than even a chair, which is where the name ‘omnivore’ sticks. Similar to the puzzle cube, our aim is to put in as much insertion as possible before we have to going into production phase.
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Visualisations
(1)
(2)
(1) Demo visualisation render of the stool. (2) Morphig Manual
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Technical Drawings
Drawing Credit: Tan
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Design & Fabrication Process We have continually adopted printin-place process for the production method of the plinth part, with the previous experiment that given uneven surfaces we went a bit anbicious and adopted mostly 0.2mm of clearance inbetween each object, which resulted in a deastic failure of two major parts being massively fused together and we have to seperate them with brutal tools.
(1). Gringing the model in a top-down process (2). Manually adding clearance using offset & fixing bad geometries (Painful) (3) Slicing Print-In_Place (4) Breaking and Assembling (5) We have to do a coat of spraypaint because we ran out of black filaments (6) Final Assemblages Assignment_05_More_Joints_and_Connections
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Design & Fabrication Process - Aluminium Profile Stool
(1). Printing connection joints (2). Sourcing main structures from a CNC supplier (3). Sourcing timber from Fablab recycle (4). Installations Assignment_05_More_Joints_and_Connections
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Demo assembly
(1). Demo Assembly with parts a printed one night before presentation Photo Credit: Tan Assignment_05_More_Joints_and_Connections
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For Lack of a Better Name Stool
For Lack of a Better Name Stool, Jingyi Liu, 2023
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What is this? A center for ants?
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3.1
Reflection Before Design AKA The existential crises of a chair: From the feedback we received from the omnivore stool, we have concluded two main issues: - The chair works as a good exploration of gimic and intriguing forms, however, the act of harshly seperating the ‘readymade’ parts and ‘designed stereotomic parts’ failed to co-exist. The chair can weakly justify itself as a holistic form without a formerly prompted justification.
(3)
- Too many gaget insertions were placed into the plinth form (1), all joints works as a toy of wonder, however they contribute little to the main purpose of a sitable stool. One fruitful act were considered successful, where the plinth is designed to friction fit the readymade v-slot channel, showcasing an unexpected tectonic of free-form interacting with a mass-produced product. With the reflection, we narrowed down our focus on assignment two, which will continuing the previous exploration of transformable chair (movable joints) and insertion of alu channel while meadiating them into a holistic form.
(1)
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(2)
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Design References & Form Finding: Basic Form The Cuba Stool by Joyride is a good example of gimmicky joints contributing to its purpose as a chair (or stool). Jointed by two hydrolic cylinders, the chairback will automatically elevate when a person sit on it. This gave the interation to achieve a similarly functionable chair with the tectonic of puzzle-ish pieces.
(1)
(3)
(2)
(1) Joyride, Cubastool (2) Joyride, Cubastool fransforming diagram A (kinda) minimalistic stool with a liftable back support when acted by a downward force (3-4) Joyride, Cubastool internal mechanics
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Design References & Form Finding: Basic Form
(1)
(2)
(3)
(4)
Mood Board (1) Jean Nouvel, Tokyo Opera House (2) Steel Cube Chair, Karl Friedrich Forster (3) Mild Steel Sheet (4) Photo of office Chair bottom lattacing, Armature Globale Assignment_05_More_Joints_and_Connections
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Planning of Movement Joints
Playstation Mode
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Side Table Mode
Stool Mode
Stool Mode 2
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Planning of Movement Joints
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Planning of Movement Joints: Angle Adjustment <10 °
5°
Slide
225mm
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Planning of Movement Joints: Parts Nodes for sliding
Chair Plate Support
Slider Nodes for installation
Elastic Joint Support Rotation Joint
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Design References & Research: Technological To furthur advance designing for additive manufacturing, Ntopology is used (i applied to their educational licensed program) as an analysis and generative tool contributing to the design, aiming to create load bearing forms with material efficiency. The Implicit modeling mode adpoted by Ntopology doesn’t explicitly calculate edges or vertices but instead uses a single mathematical function to describe a 3D solid body, making a fast and efficient way to model complex part geometry such as rapidly creating various iteration
(1)
of generative form and complex lattcing structures.
SPOILALERT: Didn’t manage to master topology optimisation in Ntop, altered to use grasshopper with Topos plugin to generate an potimised model for (1)
(2)
formal/structural development.
(1-2) Examples from Ntopology Software: https://www.ntop.com/ (3) Carlos Calvo Cristóbal, Typology optimised footrest and footguard Assignment_05_More_Joints_and_Connections
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Topology Optimisation
Manual Optimisation
Topology Optimisation
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Mix Material: PLA + TPU Merging
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3.6
Mix Material: PLA + TPU Merging
Gyroid
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Schwarz
Diamond
Lidnoid
SplitP
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Production
1. A quick clearance demo designed to test out what kind of gaps need to considered in digital modelling process to enable either smooth movement joints or tight fitting joints. 2. Seperated chunk were printed with a layer of PLA supporting material (PVA composite) that is a easy to peel off when dismentalling the support, this allows the support to be place with zero offset and guarantee best finishing and accuracy. 3. Parts of the model were modelled and printed without consideration for screw clearance, therefore parts of the print needs to be routed with a table router. Assignment_05_More_Joints_and_Connections
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Installation Process: Gluing chunks together.
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Technoblade Stool
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4.1
Final Project Expectations
As for the final piece, I have decided to work on perfecting the mechanic details and lightweighting of the Assignment 2 stool. The goal is to keep what is currently working (as an example the main mechanism and the overall composition) and construct a more refined prototype that is material efficient and as open-sourcable as possible. The technoblade stool should be easily producable with a consumer grade household 3d printer and a set of easily sourced readymade products. The second layer of intension is trying to find the balance point of topology-optimised-form and the crafted-form. Topology-optimized forms are undboubtly the most materially efficient geometry to serve its load bearing function, and this fluid language has often been expressed as a showcase or menifestation. This project will navigates on a synthesis, blending algorithmic fluidity with geometric rigidity, ensuring progressive designs remain anchored in foundational principles.
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4.2
Topology Optimisation Input Preparation in Rhino
Preferred Zone - Bias Frame
No Go Zone - Storage
Total Mass - Boundry
‘Shell’ Prepared for optimisation
Geometries inherited from the previous stool prototype were divided and prepared to represent zones served for different calculative properties. Mechanical parts (for example, cavity allowing flexible joint) were kept as solid, to navigate a high tendency of generating geometries in that section, while the rest were kept empty making the mass to be purely generated based on load cases.
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4.2
Topology Optimisation Input Preparation
Objects Import to Ntop
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4.2
Topology Optimisation Input Preparation in Ntop
Surfaces in the cad file were extraced to distribute essential load cases, such as basic loading force of 1140N (stand chair load), shear forces for non-centraled sitting position (basically allowing people to figet on the chair) and V-Slot Supporting forces.
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Topology Optimisation Distributing Nodes / Density for Optimisation
Setting up material properties and converting geometries to FE Bodies: The simuilated FE material properties are aligned with the 3d filament that will be used for the project. The infill density is pre-determined to be 15% with 3 shells, shells density are not inputed (bonus strength).
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Topology Optimisation Setting Up Load Cases
Prepared Forces were then Grouped in to jointed forces of
Structural
Compilance
Respose. These five groups were tested and generated multiple times with changes of distributed forces and biases.
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Topology Optimisation Running Optimisation
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4.2
Topology Optimisation Optimisation Variants Output
Final Iteration
Balancing all cases
Trying to be more lightweight...
Thrid (somewhat) iteration
Second iteration
First try:
Increasing boundry bias and
Increasing v-slot rigidity
increasing shearforce and
Reducing loading capacity
Including v-slots as load bearing
minimising object density change
of V-slots to minimum
penalty
also adding backplate as a part of mass bias
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Formal Optimisation Stacking Smoothen form with origional simulated form
Refined Optimisation
Accurate Optimisation
(Smoothen Body then converted
(Mesh)
to CAD)
To joint the raw data into pre-existing chair in a coherent formal language, two sets of optimisation model were simply stacked with the rhino model as a reference point. Before the start of modelling, the aesthetic of automobiles were heavily referenced since they share a similar process of translating enginerically optimised data to a crafted form.
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Formal Optimisation Just Painfully model the thing out :(
This maunal modelling process start with blocking and then slowly traforming to intersected blocky ‘creases’ following with one entire filliting in the end. I have decided to model the entire geometry in Nurbs software (rhino) but with a mesh modelling mindset. Its just painful, i have nothing else to say, you have to carefully calculate the junction of every single surfaces and imagine the creases and the worse part is to imagine those non-existstant n-gons! If you got lazy and ignore it its a guarantee the final filliting will not work. Its just painful, why am i doing this to myself, erhhhhh! Oh and by the way i made the front symmetrical because it follows the overall composition but the rest are not because thats how it is form in the optimisation process, figuring that out is just another layer of pain :(
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Preparaing for Fabrication Seperating the geometry based on mechanical/production constaints
Printed Sideways to reduce Sliding Friction
Seperated Shells to match with print orientation with the rest
Mass is seperated into chunks that does Printed upright to generate minimal support
not exceed a bounding box of 250x250 (normal print volume of most of household 3d printers) with parts printed side ways to reduce sliding channel friction.
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4.4
Planning the prints Seperating the geometry based on mechanical/production constaints
Planning and labeling prints to seperated jobs, prints were not crambed into minimal print bed in case of print failure. Parts were assigned with different infill density and shell thickness according to its mechanical function (for eg parts that needs more fixture were slightly stronger)
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4.5
Fabrication Surface finishing Mild Steel
Metal lazercutted mild steel were treated with the following process: 1. Sanding (to get rid of pre-existed rust) 2. Polishing 3. Applied with Metal Kleen protection wax
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Printing Cutting Template for V-Slot
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Putting Everything Together...
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