DF_LAB_Summer_2022 by Min Ghi

DF_LAB Michael Minghi Park - 921549 Studio Leaders: Darcy Zelenko & Mitchell Ransome

DF_Lab_SUM_2022

G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0 G0

X517.38 Z100.00 X513.05 X513.08 X513.11 X513.15 X513.19 X513.23 X513.27 X513.32 X513.37 X513.42 X513.47 X513.52 X513.58 X513.64 X513.70 X513.76 X513.82 X513.89 X513.96 X514.03 X514.11 X514.18 X514.26 X514.34 X514.43 X514.52 X514.61 X514.70 X514.80 X514.90 X515.00 X515.11 X515.21 X515.32 X515.44 X515.55 X515.67 X515.78 X515.91 X516.03 X516.15 X516.28 X516.41 X516.54 X516.67 X516.81 X516.94 X517.08 X257.87 X257.73 X257.60 X257.46 X257.33 X257.20 X257.06 X256.93 X256.79 X256.66 X256.52 X256.39 X256.26 X256.12 X255.99 X255.85 X255.72 X255.58 X255.45 X255.32 X255.18 X255.05 X254.91 X254.78 X254.65 X254.51 X254.38 X254.24 X254.11 X253.97 X253.84 X253.71 X253.57 X253.44 X253.30 X253.17 X253.03 X252.90 X252.77 X252.63 X252.50 X252.36 X252.23 X252.10 X251.96 X251.83 X251.69 X251.56 X517.38 X401.17 X288.58 X257.87 X293.73 X293.72 X292.44 X290.68 X289.54 X288.51 X284.62 X278.92 X270.33 X265.41 X260.87 X259.82 X258.78 X257.73 X517.08 X497.83 X478.02 X458.76 X439.13 X420.58 X400.98 X400.84

Y121.23 Y221.14 Z513.05 F1500 Y219.10 Z513.08 F1500 Y217.06 Z513.11 F1500 Y215.02 Z513.15 F1500 Y212.98 Z513.19 F1500 Y210.94 Z513.23 F1500 Y208.89 Z513.27 F1500 Y206.85 Z513.32 F1500 Y204.81 Z513.37 F1500 Y202.77 Z513.42 F1500 Y200.73 Z513.47 F1500 Y198.69 Z513.52 F1500 Y196.65 Z513.58 F1500 Y194.61 Z513.64 F1500 Y192.57 Z513.70 F1500 Y190.53 Z513.76 F1500 Y188.49 Z513.82 F1500 Y186.45 Z513.89 F1500 Y184.41 Z513.96 F1500 Y182.37 Z514.03 F1500 Y180.33 Z514.11 F1500 Y178.29 Z514.18 F1500 Y176.25 Z514.26 F1500 Y174.21 Z514.34 F1500 Y172.17 Z514.43 F1500 Y170.13 Z514.52 F1500 Y168.10 Z514.61 F1500 Y166.06 Z514.70 F1500 Y164.02 Z514.80 F1500 Y161.98 Z514.90 F1500 Y159.94 Z515.00 F1500 Y157.90 Z515.11 F1500 Y155.86 Z515.21 F1500 Y153.82 Z515.32 F1500 Y151.79 Z515.44 F1500 Y149.75 Z515.55 F1500 Y147.71 Z515.67 F1500 Y145.67 Z515.78 F1500 Y143.64 Z515.91 F1500 Y141.60 Z516.03 F1500 Y139.56 Z516.15 F1500 Y137.52 Z516.28 F1500 Y135.49 Z516.41 F1500 Y133.45 Z516.54 F1500 Y131.41 Z516.67 F1500 Y129.38 Z516.81 F1500 Y127.34 Z516.94 F1500 Y125.30 Z517.08 F1500 Y91.90 Z257.87 F1500 Y94.67 Z257.73 F1500 Y97.44 Z257.60 F1500 Y100.21 Z257.46 F1500 Y102.97 Z257.33 F1500 Y105.74 Z257.20 F1500 Y108.51 Z257.06 F1500 Y111.27 Z256.93 F1500 Y114.04 Z256.79 F1500 Y116.81 Z256.66 F1500 Y119.58 Z256.52 F1500 Y122.34 Z256.39 F1500 Y125.11 Z256.26 F1500 Y127.88 Z256.12 F1500 Y130.65 Z255.99 F1500 Y133.41 Z255.85 F1500 Y136.18 Z255.72 F1500 Y138.95 Z255.58 F1500 Y141.72 Z255.45 F1500 Y144.48 Z255.32 F1500 Y147.25 Z255.18 F1500 Y150.02 Z255.05 F1500 Y152.79 Z254.91 F1500 Y155.55 Z254.78 F1500 Y158.32 Z254.65 F1500 Y161.09 Z254.51 F1500 Y163.85 Z254.38 F1500 Y166.62 Z254.24 F1500 Y169.39 Z254.11 F1500 Y172.16 Z253.97 F1500 Y174.92 Z253.84 F1500 Y177.69 Z253.71 F1500 Y180.46 Z253.57 F1500 Y183.23 Z253.44 F1500 Y185.99 Z253.30 F1500 Y188.76 Z253.17 F1500 Y191.53 Z253.03 F1500 Y194.30 Z252.90 F1500 Y197.06 Z252.77 F1500 Y199.83 Z252.63 F1500 Y202.60 Z252.50 F1500 Y205.36 Z252.36 F1500 Y208.13 Z252.23 F1500 Y210.90 Z252.10 F1500 Y213.67 Z251.96 F1500 Y216.43 Z251.83 F1500 Y219.20 Z251.69 F1500 Y221.97 Z251.56 F1500 Y121.23 Z517.38 F1500 Y114.76 Z401.17 F1500 Y99.17 Z288.58 F1500 Y91.90 Z257.87 F1500 Y100.24 Z293.73 F1500 Y100.24 Z293.72 F1500 Y100.04 Z292.44 F1500 Y99.77 Z290.68 F1500 Y99.59 Z289.54 F1500 Y99.44 Z288.51 F1500 Y98.83 Z284.62 F1500 Y97.95 Z278.92 F1500 Y96.62 Z270.33 F1500 Y95.86 Z265.41 F1500 Y95.16 Z260.87 F1500 Y94.99 Z259.82 F1500 Y94.83 Z258.78 F1500 Y94.67 Z257.73 F1500 Y125.30 Z517.08 F1500 Y124.25 Z497.83 F1500 Y123.17 Z478.02 F1500 Y122.12 Z458.76 F1500 Y121.05 Z439.13 F1500 Y120.03 Z420.58 F1500 Y118.96 Z400.98 F1500 Y118.94 Z400.84 F1500

X395.84 X386.12 X376.56 X366.89 X361.33 X355.78 X350.21 X346.12 X342.03 X337.94 X328.33 X256.39 X256.26 X256.12 X255.99 X255.85 X255.72 X255.58 X255.45 X255.32 X255.18 X255.05 X254.91 X254.78 X254.65 X254.51 X254.38 X254.24 X254.11 X253.97 X253.57 X256.39 X256.26 X256.12 X255.99 X255.85 X255.72 X255.58 X255.45 X255.32 X255.18 X255.05 X254.91 X254.78 X254.65 X254.51 X254.38 X254.24 X254.11 X253.97 X253.84 X253.71 X253.57 X309.33 X309.25 X396.12 X386.40 X376.75 X367.02 X357.28 X347.74 X338.01 X330.39 X322.85 X315.26 X313.79 X312.31 X310.84 X310.24 X309.65 X309.05 X306.71 X304.38 X302.04 X294.84 X287.74 X280.54 X279.33 X278.11 X276.90 X268.62 X260.37 X252.12 X251.93 X251.75 X251.56 X513.08 X494.11 X473.64 X454.65 X434.61 X416.52 X396.54 X396.44 X396.34 X396.24 X386.63 X376.87 X367.22 X357.41 X348.11 X338.31 X329.07 X319.90 X310.73 X310.31 X309.89 X309.47 X299.91 X290.68 X281.07 X271.59 X262.22 X252.80 X252.34 X251.88 X251.42 X513.05 X396.35 X281.39 X251.29 X251.29 Z0.00 G28 M30

Y209.34 Y209.82 Y212.48 Y213.00 Y213.30 Y213.60 Y213.90 Y214.12 Y214.34 Y214.56 Y215.08 Y122.34 Y125.11 Y127.88 Y130.65 Y133.41 Y136.18 Y138.95 Y141.72 Y144.48 Y147.25 Y150.02 Y152.79 Y155.55 Y158.32 Y161.09 Y163.85 Y166.62 Y169.39 Y172.16 Y180.46 Y122.34 Y125.11 Y127.88 Y130.65 Y133.41 Y136.18 Y138.95 Y141.72 Y144.48 Y147.25 Y150.02 Y152.79 Y155.55 Y158.32 Y161.09 Y163.85 Y166.62 Y169.39 Y172.16 Y174.92 Y177.69 Y180.46 Y216.10 Y216.10 Y213.51 Y213.77 Y214.02 Y214.28 Y214.54 Y214.80 Y215.06 Y215.26 Y215.46 Y215.66 Y215.70 Y215.74 Y215.78 Y215.84 Y215.90 Y215.97 Y216.21 Y216.45 Y216.70 Y217.45 Y218.19 Y218.94 Y219.07 Y219.20 Y219.32 Y220.19 Y221.05 Y221.91 Y221.93 Y221.95 Y221.97 Y219.10 Y218.53 Y217.91 Y217.34 Y216.74 Y216.20 Y215.60 Y215.60 Y215.60 Y215.60 Y215.89 Y216.18 Y216.47 Y216.76 Y217.04 Y217.33 Y217.60 Y217.88 Y218.15 Y218.19 Y218.24 Y218.29 Y219.35 Y220.38 Y221.44 Y222.50 Y223.54 Y224.58 Y224.63 Y224.68 Y224.74 Y221.14 Y217.70 Y223.35 Y227.50 Y227.50

Z395.84 Z386.12 Z376.56 Z366.89 Z361.33 Z355.78 Z350.21 Z346.12 Z342.03 Z337.94 Z328.33 Z256.39 Z256.26 Z256.12 Z255.99 Z255.85 Z255.72 Z255.58 Z255.45 Z255.32 Z255.18 Z255.05 Z254.91 Z254.78 Z254.65 Z254.51 Z254.38 Z254.24 Z254.11 Z253.97 Z253.57 Z256.39 Z256.26 Z256.12 Z255.99 Z255.85 Z255.72 Z255.58 Z255.45 Z255.32 Z255.18 Z255.05 Z254.91 Z254.78 Z254.65 Z254.51 Z254.38 Z254.24 Z254.11 Z253.97 Z253.84 Z253.71 Z253.57 Z309.33 Z309.25 Z396.12 Z386.40 Z376.75 Z367.02 Z357.28 Z347.74 Z338.01 Z330.39 Z322.85 Z315.26 Z313.79 Z312.31 Z310.84 Z310.24 Z309.65 Z309.05 Z306.71 Z304.38 Z302.04 Z294.84 Z287.74 Z280.54 Z279.33 Z278.11 Z276.90 Z268.62 Z260.37 Z252.12 Z251.93 Z251.75 Z251.56 Z513.08 Z494.11 Z473.64 Z454.65 Z434.61 Z416.52 Z396.54 Z396.44 Z396.34 Z396.24 Z386.63 Z376.87 Z367.22 Z357.41 Z348.11 Z338.31 Z329.07 Z319.90 Z310.73 Z310.31 Z309.89 Z309.47 Z299.91 Z290.68 Z281.07 Z271.59 Z262.22 Z252.80 Z252.34 Z251.88 Z251.42 Z513.05 Z396.35 Z281.39 Z251.29

F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500 F1500

_Contents

Week_01_A_Establishing Week_01_B_Project_Analysis Week_02_A_Build Week_02_B_Draw

page 4 - 33

page 34 - 109

Week_03_A_Build Week_03_B_Draw Week_03_C_Prototype

page 110 - 185

Week_04_A_Build Week_04_B_Draw

page 186 - 225

Week_05_A_Build Week_05_B_Draw

page 226 - 249

Week_06_A_Build Week_06_B_Draw Week_06_C_Prototyping

page 250 - 307

Week_07_A_Build_Build_Build

page 308 - 317

All drawings, photos, and annotations included in this journal have been produced personally. All external works and resources have been outlined and referenced.

DF_Lab_SUM_2022

_WEEK_01_A Establishing the project

DF_LAB investigates the implications of advanced fabrication techniques on the construction of complex structures. Through a iterative process (prototyping), the team would develop and refine methods of designing for ‘manufacturing and assembly’ (DfMA). CNC machining is the primary fabrication technique utilized in the project. This methodology allows for the fabrication of complex geometry using up to 4-axis of manipulation. The project would incorporate logics of computational design to increase accuracy, consistency and fabricability of the artefacts. Furthermore, computational methods could be used to increase variability and produce greater design potential for future iterations. The primary material used for fabrication is the Spotted Gum (Corymbia maculate). The wood has been selected due to its high durability, strength, appearance, and availability. The project incorporates aspects from these 3 major fabrication parameters – the fabrication technique, computational design, and materiality. The overall objective is to optimise the production process and design outcome. Furthermore, the project should incorporate the characteristics of the site and its users into the design. A successful project would produce a spatial outcome that re-activates the site.

DF_Lab_SUM_2022

_Branching_structures

Load path

General nature of branching structures Branching structures follow the basic geometric principles of trees found in nature. Fundamentally, the structure expands from one point (node) to multiple branches (straights). Following this structural logic, the reach of the branch is proportional to the surface area that can be supported. In this system, the loads from the supported surface/structure are transferred through the branches to a concentrated point, often a column. This division of loads allows for smaller structural members, reducing material use. Furthermore, the shorter length of each member results in greater resistance against buckling. As a result, branching structures produce efficient load path systems.

Wind action

Gravity action

Mechanical behaviour of branching structures The main structural characteristic of branching structures (both naturally occurring and manufactured) is their capacity to support large surface area through fractal load distribution. The transferring of loads from a large surface area to a concentrated point, often a column, has both aesthetic and structural advantages. Naturally occurring trees are able to reduce loading through deformation. Furthermore, bending moments are absorbed through the root system. Trees are vulnerable from vertical dead-loads and wind-loads due to its large surface area. Artificial branch structures are more vulnerable to bending moments because of its lack of root system. This can be mitigated by introducing a footing or foundation system. Branching structures are mainly subjected to tensile and compressive forces. These forces can be counteracted by efficient structural design – reducing the length of straight members to minimise buckling, streamlining and reducing material use.

DF_Lab_SUM_2022

_Producing_branching_structures

Iteration 1

Iteration 2

Iteration 3

Iteration 4

Iteration 5

Producing branching through fractal logic Fractal logic can be used to produce branching structures. Fractal geometries utilize multiple iterations of non-regular mathematical rules. A non-regular geometry is produced through a series of repetition.

Input curve

cto

r le

Angle

Production rules

Iteration 2

Iteration 3

Producing branching through l-system logic L-system consists of an alphabet of symbols. These symbols are used to produce ‘strings’ – a collection of production rules that expand each symbol into larger strings. Fundamentally, L-systems are produced through an initial ‘axiom’ string. The axiom string is then manipulated through a pre-determined mechanism which translates the generated strings into geometry. L systems follow a fixed production rule which is repeated through each generation/iteration. Each generation initiates from a starting point. A collection of lines is produced according to defined parameters – angles, length, and quantity.

DF_Lab_SUM_2022

_AA’s_Hooke_Park

General description – AA’s Hooke Park There have been several projects at the AA’s satellite Hooke Park campus that embody a similar ethos to our current fabrication efforts. This remote campus is Design + Make’s headquarters for architectural research. Here, majority of the research is conducted through 1:1 fabrication and prototyping of bespoke timber structures. The programme looks at three core aspects of fabrication – advanced technologies, craft techniques, and materiality. The research team proposes that novel digital fabrication methodologies could lead to a reinvention of the traditional definition of ‘making’ and ‘craft’. Emerging tools such as 3D scanning, generative modelling and robotic fabrication are investigated to find new opportunities in design and making. Primarily, the research group investigates ways in which these high-resolution tools could be used to foster a more cohesive relationship between the designer and the process of fabrication – both digital and physical.

Wakeford Skeleton This skeleton structure would later provide a structural framework for the library. This project is part of ‘Wakeford Hall’ which is a multi-purpose academic for the students on the AA’s Hooke Park campus. The development of the Wakeford Skeleton adopts methodologies that were iterated throughout previous projects. This methodology involves drawing, physical model making and prototyping. The Wakeford Skeleton project produced novel techniques to produce bespoke laminated frames. This technique took account of the process of industrial timber lamination. Individual segments of the laminated timber frame (14 frames) were shaped through a subtractive technique. This technique involved the use of robot mounted bandsaw which allowed for 6-axis milling.

Image Retrived From: httpsdesignandmake.aaschool.ac.ukassetsprojec…eford-skeleton06_WakefordSkeleton_ AitorAlmarez httpsdesignandmake.aaschool.ac.ukassetsprojec…eford-skeleton09_WakefordSkeleton_VedaBarath

DF_Lab_SUM_2022

_AA’s_Hooke_Park

3D Scanning Several projects at the AA’s Hooke Park involves 3D scanning techniques. By producing a thorough 3D scanned environment, the designers can incorporate reliable site information into their designs and fabrication methods. Furthermore, a 3D lidar survey of the assembled structure enables analysis of assembly tolerances to inform future fabrication strategies.

Image Retrived From: https://designandmake.aaschool.ac.uk/assets/project/campus-scanning/cover.jpg httpsdesignandmake.aaschool.ac.ukassetsprojec…eford-skeleton02_WakefordSkeleton_ZacharyMollica httpsdesignandmake.aaschool.ac.ukassetsprojec…eford-skeleton01_WakefordSkeleton_ZacharyMollica

DF_Lab_SUM_2022

_FutureTree

General description – FutureTree by Gramazio Kohler Research The FutureTree project, Esslingen by Gramazio Kohler Research is another project that share various similarities with DF_Lab. The canopy structure is fabricated with complex timber members that were designed, optimised, and manipulated through computational techniques. The crown of the structure is comprised of 380 individual timber elements. This canopy element is supported by a concrete column. Two sides of the canopy structure are attached to the building for support. The remaining two sides are cantilevered. The project investigates ways in which material-use could be minimised through structural and geometric optimisation. The frame’s geometry is informed by its structural behaviour – the opening of the ‘reciprocal knots’ are manipulated to achieve higher stiffness in the cantilevering sides. The timber used for the project is acetylated pine wood. This type of timber is widely used throughout Europe because of its durability. The wood is treated with a process called ‘Acetylation’ which radiata pine from New Zealand is soaked in acetic anhydride. This produces pine that is more resistant to moisture, insects, and rot. Furthermore, the process reduces shrinking and swelling. This makes the material more suitable for complex fabrication process which require consistency and accuracy from its base materials.

Stem connection The ‘stem’ section of the Future Tree, by Gramazio Kohler Research, is a reinforced concrete column. The column was fabricated with an ultra-thin robotically 3D printed framwork. This formwork was then combined with a fast-hardening concrete. GKR calls this composite structural technique ‘eggshell’. Through this technique, the architects were able to fabricate a structurally and topologically optimised concrete structure, whilst integrating standard reinforcement and minimizing formwork. As a result, the project achieved an efficient workflow regarding economic and sustainability.

Image Retrived From: 191030_234_FutureTree_Diagrams_Screw_Detail1_Aleksandra_Apolinarska_WM 191203_234_FutureTree_Final_Crown_Joris_Burger_WM

DF_Lab_SUM_2022

_MycoTree PRECEDENT STUDY BLOCK RESEARCH GROUP - MYCOTREE

GEOMETRIC WORKFLOW

COMPUTATIONAL WORKFLOW

FABRICATION WORKFLOW

General description – MycoTree by Block Resarch Group The MycoTree project by Block Research Group share various similarities with our fabrication project at DF_Lab. Like our project, MycoTree is a spatial branching structure. The project thoroughly investigates the impact of materiality on the fabrication process. In particular, the use of a novel material such as mycelium provided limitations to the project. These limitations, which ranged from structural integrity to transportation of building material, were overcome through use of computational tools and prototyping.

Image Retrived From: httpsblock.arch.ethz.chbrgimagescache06_mycotree_production_carlinateteris_16x9_1504423374_960x540

Geometric similarities with DF_Lab The geometric similarities between the MycoTree and DF_Lab are obvious; both projects are spatial branching structures that contain nodes and bridging (straight) sections. Both projects were complicated by the existence of multiple tendons that exists on differing planes. This increased the complexity of the node fabrication process. In the MycoTree project, this complication was resolved through the use of bespoke moulds that allowed for the fabrication of complex 3D geometries. With the DF_Lab project, a 4-Axis CNC router is utilized to fabricate tendons at different planes. The main difference between the two project is the overall project objective. MycoTree is concerned more heavily on the implications of novel materials on the process of digital fabrication. Whereas DF_Lab investigates the implications of advanced fabrication techniques on the construction of complex structures.

DF_Lab_SUM_2022

_Material_Research

General Material Characteristics Spotted gum (Corymbia maculate) is a hardwood endemic to Eastern Australia. There are four species that grow along the East coast, from Northeast Victoria to Northern Queensland. Sawn timber from Spotted Gum is generally available throughout Australia. It is widely used in structural, exterior and interior applications because of its high durability and strength. It has a striking appearance with its back-sawn grain structure, attractive markings and vibrant colour palette. Back-sawn boards are cut so that the faces of the boards are tangential to the annual growth rings. The wood has a ‘greasy’ feel which is a characteristic that is beneficial during machining and boring. It is a minimal staining timber since it is less prone to bleed-through of tannins. Spotted gum readily accepts paint, stains and polish. Spotted Gum is used across a wide range of engineering applications including wharf and bridge construction, railway sleepers, and mining timbers. It is also suitable for a range of building applications, such as posts, poles, framing, and cladding. The wood is used in boatbuilding, and for handles of tools that are subject to high impact forces. Spotted Gum is also suitable as carving and woodturning and is used in the manufacture of both indoor and outdoor furniture.

Typical residential application of spotted gum

Relevance of the material The material characteristics of spotted gum are highly compatible with the nature of the project. Its high durability and strength makes it viable as an outdoor spatial installation. It is highly dense and homogenous which increases its workability under a CNC router. Furthermore, the material is sourced locally which reduces the overal carbon footprint of the project

Image Retrived From: https://www.havwoods.com/au/news/what-is-spotted-gum-timber/ https://ramienstimber.com.au/various-range-of-timber-products/categories/decking-screening-timbers/ hardwood-decking-spotted-gum/

DF_Lab_SUM_2022

_Fabrication_Material

Specific Material Properties The project initially acquired 19 pieces of rough-sawn spotted gum. The typical dimensions for the wood was 145x45x2100mm. All pieces had a pre-camber that ranged from negligible to significant. The spotted gum planks required a dressing process to increase the material consistency and workability across the projects. Segmenting the wood would also reduce the severity of the camber. This would reduce the amount of timber that would need to be eliminated.

Sorting of wood

Colour variations

Imperfections on surface (Knots)

Inconsistencies within the material There were several material inconsistencies and imperfections with the acquired material sample. There were visual inconsistencies with the level of colour saturation. Some pieces were much more reddish than others. This could impact the visual consistency of the assembled structure. There was also a distribution of knots that were visible on the plank surface. This could reduce the machine accuracy and consistency during the milling phase.

DF_Lab_SUM_2022

_WEEK_01_B Project Analysis

The structure was segmented into 4 aggregates. This allowed for more efficient distribution of tasks and labour. Each group was allocated a specific aggregate to analyse, document and fabricate. Our group members for DF_LAB was Jack M Zhang, Ling Tia, and myself. The allocated aggregate was analysed in regards to its size, and complexity. The information gathered from this analysis was used to determine the approporiate fabrication method; most ‘nodes’ and ‘ends’ pieces were more suitable for 3-axis flip milling whereas ‘straights’ required 4-axis rotation milling. Nesting was prepared in pursuant to the approporiate fabrication method. Furthermore, considerations were made regarding material colour, part location, stock size, and material imperfections. Some concerns for the projects were the limited number of timber stock, time constraints and unfamiliarity with fabrication method.

DF_Lab_SUM_2022

_Fabrication_Geometry

Type

Number

Parts

end end end node node node node node straight straight straight straight straight straight

8 13 27 N13-S1(0) N21-S1(0) N27-S1(0) N7-S1(0) N8-S1(0) S13-21 S2-7 S21-8 S26-27 S27-7 S7-8

2 2 2 6 6 6 6 6 2 2-3 2 1 2 2 47-48 total

Segmentation of structure into chunks The overall structure (whole) was segmented into several smaller aggregates. This was done to distribute the fabrication workload between the 4 groups of students. The diagram above illustrates the particular piece of aggregate that our group was allocated. Our particular aggregate contained 14 individual parts - 3 ends, 5 nodes, and 6 straights. The actual number of geometries produced for ‘nesting’ was 48 pieces. This was due to two factors; each node was segmented into 3 to accomodate for the ‘branching’; all pieces were further divided into 2 halves to accomodate a circular hollow channel for services.

45mm

2.9

45mm

7.5

45mm

8.4

‘Ends’ There were 3 individual ‘ends’ pieces within our allocated aggregate. Most of the end pieces had dimensions which exceeded the capacity of the 4-axis CNC router. Therefore, the end pieces were decided to be milled using the 3-axis CNC router. To accomodate for this, each end piece was segmented into 2 halves along the x-y plane. This was necessary to eliminate any undercuts within the geometry.

DF_Lab_SUM_2022

_Fabrication_Geometry

31.

N7-S0

45mm

N13-S1

m mm

6.9

N8-S1

N21-S1

45mm

122

mm mm

3.2

116

N13-S1

45mm

N8-S1 70

N21-S1

9.8

45mm

N7-S0

N27-S1

8.6

N27-S1

45mm

‘Nodes’ There were 5 individual ‘nodes’ pieces within our allocated aggregate. The ‘nodes’ were the most complex category to nest and fabricate. This was due to their intricate locking/joinery system which allowed for branching. The strategy for nesting was to assign a single plank of spotted oak to an individual ‘node’. This would maximise the visual and structural consistency of individual ‘node’ pieces. Furthermore, all pieces was nested in parallel to further increase this consistency.

135mm

S2-7

90mm

S7-8

3.8

4.7

S21-8 S21-8

90mm

S13-21

5.5

S26-27

45mm

S7-8

S27-7

90mm

S26-27

8.6

S2-7

S13-21

90mm

S27-7

5.1

6.1

‘Straights’ There were 6 individual ‘straight’ pieces within our allocate aggregate. The complexity of fabricating ‘straight’ pieces arose from its tendons; each ‘straight’ pieces had two tendons on either sides that were orientated at different planes. Therefore, ‘straight’ pieces were planned to be milled using a 4-axis CNC router. Many of the straight pieces exceeded the dimensions of the spotted oak plank. To accomodate for this, pieces of the plank was laminated to increase its z-axis dimension.

DF_Lab_SUM_2022

_Nesting_Process

Ideal dimensions of Spotted Gum

Real-life cambering

Trimming and dressing

Location pins

Base material variables In preparation for ‘nesting’, material and dimensional variables of timber was considered. Many of the sample timber planks had significant degree of bowing. To address this, all of the timber planks were decided to be segmented and dressed. This process altered the dimensions of the planks which had to be considered during the nesting phase.

Grain direction

Edge offset to reduce vibration

Colour variation of timber

Knots and other inconsistencies

Printing & Nesting parameters Several nesting strategies were adopted to increase visual and structural consistency. All parts were to be printed in parallel to the grain direction. A 13mm offset distance was adopted along the timber perimeter to minimise the effect of vibration during CNC milling. All printing geometries belonging to the same part would be printed on the same plank to ensure colour consistency. Surface knots and other visual inconsistancies should be considered.

DF_Lab_SUM_2022

_Computational_Flowchart

Simplify variables

Initial variables

Nesting bed

Nesting bed x19

Printing geometries

Nesting algorithm

Nesting result x19

Printing geometries 4-5

Computational strategy & estimating The overall nesting strategy was two-stepped. Initially, all of the printing geometries and printing bed was simplified into bounding boxes to obtain an area estimation. These volumes were parameterised by extracting the area of the top face. These area values were then inputted into a nesting algorithm to find the most efficient nesting arrangement. The nesting algorithm yielded a minimum bed count of 5 planks. This estimate was then used as a guide for the secondary phase of manual adjusting.

Specify variables

Manual nesting

Nesting bed

Nesting outcome

Nesting

Nesting configuration

Printing geometries

Manual adjustment & optimising Once the computational minimum of 5 planks was optained, a manual nesting phase was conducted. The printing geometries were adjusted in consideration of the ‘Base material variables’ and the ‘Printing and nesting parameters’. The computational estimate of 5 planks was maintained throughout the manual adjustment phase. Ultimately, the cumulative nesting effort resulted in an efficient and effective arrangement of printing geometries.

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_Nesting Timber A (1)

-S0

Timber B.

-7

1-8

S2 8

Config 1

Timber C

-21

6-2

S13 13

-8

Config 2 (1)

Timber D

0 1-S

-7 27

S 27

Config 3

(1)

S0 13-

0) -S(

Timber E

Config 4 )

0(1

-S N8

Config 5

Allocation of timber The 5 printing configurations had unique maximum depths and distribution densities. Because of this, it was important to consider the allocation of timber for each configuration; Configuration 5 had the smallest maximum printing depth. Therefore, Timber E, which had the greatest degree of bowing, was allocated to config 5. This was to allow for the loss of timber depth during the dressing phase.

Timber A

Timber B

Timber C

Timber D

Timber E

Minimum clearance = 2mm

Timber A 1200mm

900mm

1200mm

900mm

1200mm

900mm

1250mm

850mm

1250mm

850mm

Timber B.

Timber C

Timber D

Timber E

Overall material efficiency = 44.2%

Printing & Nesting parameters As discussed previously, each of 5 nesting configurations were allocated to an approporiate timber. Ultimately, a material efficiency of 44.2% was obtained, where ME = cumulative ‘top area’ of printing geometry / cumulative ‘top area’ of printing bed.

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_WEEK_02_A Build

In week 2, our group entered the preliminary phase of physical fabrication. Timber planks were analysed, dressed, measured, labelled and digitised in preparation for 3-axis CNC operations. These processes were informed by the preliminary nesting that was conducted in week 1. There was a feedback process between the digital nesting model and the physical timber planks. Various machines and tools within the MSD Machine Workshop were utilized during this preliminary phase. At the end of this preparatory phase, detailed measurements were made with the timber planks. As predicted, there were significant reduction to the dimensions of the planks. In response to this, an updated digital model of the planks were created. A secondary nesting was performed in respect to the updated timber dimensions. Once an acceptable nesting configuration was achieved, the nesting file was further developed in preparation for the 3-axis CNC operation. During this phase, the various digital geometries within the nesting file were sorted into specific layers. These layers corresponded to the types of CNC milling operations. Once a CNC file had been prepared, a printing sequence was inputted to the CNC router. This process involved detailed consultation with the FabLab technicians.

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_Dressing_Preparing

Measuring, allocating and segmenting Three preparatory actions occured prior to the dressing of timber planks. Initially, 5 pieces of timber were identified and labelled from the starting sample of 19. The 5 pieces of timber were strategically selected by considering colour, grain and bowing consistency. This ensured that the subsequent fabrication techniques could be applied with minimum adjustments. This would streamline the fabrication process and save time. Once the 5 pieces of timber were identified, they were allocated a unique nesting configuration - A,B,C,D, and E. Timber A,B,and C had similar nesting arrangments. These timber planks were cut at the 1200mm mark. 3 pieces at 1200mm and 3 pieces at 900mm were produced. Timber D, and E had similar nesting arrangments. These timber planks were cut at the 1250mm mark. 2 pieces at 1250mm and 2 pieces at 850mm were produced. Timber D, and E had the smallest ‘maximum nesting depth’. Therefore, the 2 pieces of timber with the greatest degree of bowing were allocated D, and E. All pieces of timber were segmented using a Mitre Saw within the MSD Machine Workshop. All subsequent wood-working activities as part of this project would be conducted within this facility.

Each piece of timber was labelled and measured. Once a piece of timber was allocated its unique nesting configuration number, a guide line was drawn in preperation for sawing.

A Mitre saw was used for an accurate cross cutting of Spotted Gum planks. The planks were segmented into 2 pieces to minimise the loss of material during the dressing phase.

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_Dressing_Process

Planer or ‘Jointer’ was used to produce a flat surface along the timber planks. It was crucial to remove the surface inconsistencies of the rough sawn timber during the dressing phase.

A Thickenesser was used to produce a consistent thickness across the wide faces of the planks. This is a crucial step in maximising the accuracy and consistency during CNC milling.

Primary objectives of dressing During the dressing phase, the primary object is to increase the workability, and consistency of the rough-sawn timber pieces. Through the utilisation of the Planer, the Spotted Gum planks were processed in preparation for subsequent dressing techniques. The Planer produces a flat and even surface with a ‘exposed cutting head’. Furthermore, this equipment can be used to produce a ‘straight edge’. This is a crucial step in increasing the workability of timber. Using the ‘machines fence’, you are able to produce a 90 degree corner reference for the planks. Once a flat side has been produced by the Planer, the timber is processed through a Thicknesser. This Thicknesser is used to process the surface parallel to the flat side that was obtained by the Planer. This technique produces two flat sides which are now parallel. Both techniques are applied to each pieces of timber. The resultant planks are then measured and labelled in preperation for a final nesting. These dressing processes are crucial to increasing the workability of timber during CNC milling. The DF_lab project involves a complex CNC milling process where the timber must be flipped over between the milling passes. Flat, parallel and consistent sides are crucial to maximise the accuracy and consistency during this milling process.

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_Dressing_Result

Confirming timber dimensions Once all 10 pieces of planks had been fully dressed, their dimensions were measured. This new set of dimensions would be used to check the feasibility of the original nesting configuration. All timber pieces lost 1mm-2mm on all flat sides. It was crucial to ensure that timber pieces A1 and A2 had height dimensions of greater than 40mm. This was since the nested printing geometry inside planks A1 and A2 had a maximum dimension of 78mm. A minimum offset of 2mm would increase the workability of the timber inside the 4-axis CNC router. There were noticeable surface knots on timber A1, B1 and D2. The locations of all significant knots were identified. Their location would be replicated in Rhino3D to visually verify the nesting.

5 occurances of significant knots were identified across 10 pieces of timber. Their locations were identified and dimensions measured.

Planks A1, B1, and D1 had significant surface knots.

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_Digitisation

Digital model of timber The digital replication of timber planks using the real-life measurements. Dimensions in red represent the updated measurements of timber.

Allocation of timber Each timber plank was allocated a specific nesting configuration. Allocations were made by analysing the compatibility between the dimensions & inconsistencies of timber with the nesting.

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_Secondary_Nesting

Final nesting After considering both the physical variables and the digital paramters, a final nesting configuration was established. During this phase, it was important to mark out the locations of significant knots and physical defects on the timber planks. This was taken into account when allocating specific nesting configuration onto planks A1, B1, and D2. The allocation of nesting had to ensure that the printing geometries did not intersect with the knots.

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_CNC_Milling_File_Preparation

Inner side of Node Plate Workholding Pipe Engrave Curve (12mm) Mortise Pocket Region Node Locating Pocketing (5mm) Stock Locating Holes (6mm) Origin 10mm Pocket (Shadow Material)

CNC pass 1 There are two stages to the 3-axis CNC milling. The first pass involves milling out the ‘inner’ elements of the printing geometries. These inner elements involve Pipe Engrave, Mortise Pocket Region, and Node Locating Pockets. Furthermore, Stock Locating Holes are milled during this pass. All stock are stablised using a workholding material which grips the stock to the edges of the 10mm Pocket region. The Shadow Material is made of MDF and is secured to the worksurface using a vacumm seal.

Flipped side of Node Plate Locating Pin Lofted Surface External Profile Parallel Finishing Region Horizontal Roughing Region Origin 10mm Pocket (Shadow Material)

CNC pass 2 The accuracy throughout this 2-stepped milling process is maintained by the location pins. This ensures that all milling operations conducted in pass-1 corresponds with pass-2. More complex milling operations are required for pass-2. The operations are conducted in 2 main phases - Horizontal roughing, and parallel finishing. In reflection, the group should have reduced the thickness of the stock material to reduce the excessive roughing operation.

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_CNC_Milling_3-Axis Digital file preparation

Preperation of CNC printing file There is a translation stage between digital geometry and physical artefact. This trasitional phase is initiated with the conversion of the digital geometry into linear tool-path. This toolpath represents the track that the machine tool-head (CNC drill) would follow. The linear tool-path polyline is then deconstructed into its constituent points. The cartesian coordinates of these points are then converted into G-code. The operator has significant control over the contents within G-code. They are able to control the speed, the sequencing of jobs/geometries, the tool type, and the movement type. The G-code is then transferred into the CNC machine. The machine translates the code into a series of movements, actions and drill operations. The important factors that contribute to accurate CNC milling results are A) Accurate measurements of the printing material B) Providing appropriate tolerances within the initial digital geometry C) Understanding of printing material

Preperation of CNC machine tool-path in RhinoCAM. The layers of the preliminary nesting files are converted to corresponding G code.

Once the machine tool-path has been created it is sent to the CNC machine as a series of instructions.

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_G_Code

Initial digital geometry

Tween, and project

Convert to polyline

Geometry into polyline Initially, the 3D geometry is converted into a continuous, and linear polyline. Often times the polyline follows a similar logic to a basic contour. The polyline is segmented into a series of linear segments that are defined by points. The cartesian coordinates of these points are integrated into g-code.

X517.38 Z100.00 X513.05 X513.08 X513.11 X513.15 X513.19 X513.23 X513.27 X513.32 X513.37 X513.42 X513.47 X513.52 X513.58 X513.64 X513.70 X514.80 X514.90 X515.00 X515.11 X515.21 X515.32 X515.44 X515.55 X515.67 X515.78 X515.91 X516.03 X516.15 X516.28 X516.41 X516.54 X516.67 X516.81 X516.94 X517.08 X257.87 X257.73 X257.60 X257.46 X257.33 X257.20 X257.06 X256.93 X256.79 X256.66 X256.52 X256.39 X256.26 X256.12 X255.99 X255.85 X255.72 X255.58 X255.45 X255.32 X255.18 X255.05 X254.91 X254.78 X254.65 X254.51 X254.38 X254.24 X254.11 X253.97 X253.84 X253.71 X253.57 X253.44 X253.30 X253.17 X253.03 X252.90 X252.77 X252.63 X252.50 X252.36 X252.23 X252.10

Rapid linear Cartesian coordinates

Feed speed

G code The basic CNC operations are performed with the g codes implemented in the A2MC. There are various types of codes that are constituents of g code. These include interpolation codes, pause code, M codes, and stop codes. There are also Motion words which further describe machine action. These Motion words describe the feed speeds, or the speed of execution.

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_CNC_Milling_3-Axis Stock preparation for milling

Once the g code has been inputted into the CNC machine, the relevant stock materials are identified and prepared for the milling process.

Before the initiation of milling, all milling materials are measured in height.

The stock materials are fixed to the printing bed to minimise the impact of vibration on the milling accuracy and consistency. Pass 1 The preparation of the milling material has significant impact on the accuracy and consistency of the milling process. It is crucial to measure and identify the z dimension of the printing material. This is especially relavant to the the DF_Lab project since all geometries are ‘flipped milled’. If the z heights of the milling materials are accounted inaccurately, the dimensions of the output geometries are compromised. Due to the aggregate nature of the project, any inaccuracy during milling add up cumulatively. This could impact the project delivery time, structural integrity, geometric accuracy negatively. Inaccuracies in design+build projects are practically unavoidable. Several pieces of geometries were printed inaccurately. Parts with significant misalignments were identified and flagged. These parts were later edited through manual operations.

DF_Lab_SUM_2022

_CNC_Milling_3-Axis Milling Pass-A

Completion of 3-axis CNC operation The elements which are milled during the first pass would later become internal cavities within the final geometries. These cavities would provide access for the 6.35mm water pipes which would activate the evaporative cooling systems. Also during the first pass, locating holes are milled along the perimater of the milling material. There are two types of locating holes; the stock locating holes would help inform the orientation of milling material during the second pass; the node locating holes would help inform the orientation of nodes during the glueing stage. 54

The exposed pipe engrave and locating holes. These cavities would be located internally within the final geometries.

Once the print is finished, excess dust is removed using an air gun.

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_CNC_Milling_3-Axis Preparation for Milling Pass-B

Completion of 3-axis CNC operation The primary concern regarding the flip milling process was the maintaining of accurate orientation between the two passes. This was mainly addressed through the use of locating pins which provided a cross-reference between passes. The locating holes were drilled during the first pass. The pins themselves were 3D printed using the HP machine. Furthermore, it was important to maintain ‘flatness’ during the second pass. There were two variables preventing this 1) The freshly milled holes and channels had protruding bits of timber 2) The milling process amplified the bowing in the milling material The protruding bits of timber were chiselled off to create a flush surface. The bowing effects were solved by inserting a plastic nail into the mid section of the printing material. This procedure is illustrated further in the following pages.

3D printed locating pins are placed within the locating holes. These pins help inform the orientation of milling material once they are flipped.

The milling materials are flipped to expose the milling surface for the second pass.

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_CNC_Milling_3-Axis Mitigating bowing effect

There was a visible bowing in the printing material for stock A1. This issue became more pronounced after milling pass A.

To resolve the bowing effect, a 10mm hole was drilled through the timber stock. The hole was located near the middle of the stock where no geometry was nested.

A Bolt anchor was installed into the CNC nesting bed.

The installed anchor sitting inside the nesting bed.

DF_Lab_SUM_2022

_CNC_Milling_3-Axis Mitigatin bowing effect

A nylon bolt was installed into the 10mm hole which was drilled previously. Mitigation of bowing effect This type of problem solving occured very frequently throughout the entirety of the project. Although these problems seem inconsequential when observed individually, they do accumulate into visible inconsistencies and misalignments during the later stages of fabrication. These could decrease structural integrity and cause set-backs in the project time line.

The nylon bolt was fastened into the stock material until the bowing effect was negligible.

The overall process resulted in the stock material sitting flush with the nesting bed.

DF_Lab_SUM_2022

_CNC_Milling_3-Axis Roughing pass

Conduction of roughing pass on side-B of milling material. CNC milling side B Once the bowing effect was mitigated, the flip-mill process was resumed. Milling of side-B involved subtracting a more complex geometry. To facilitate more complex geometries, the milling process was conducted across two steps. The first step/pass was the ‘roughing’ where a rough silhouette of the geometry was milled.

The rough silhouette of the geometry obtained after the ‘roughing’ phase.

The CNC mill is equiped with the approproiate drill type/size between each phase of milling.

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_CNC_Milling_3-Axis Parallel finishing

The changing of drill types using the TCC (Tool Change Carousel) Parallel finishing Once a rough silhouette of the geometry is achieved, the drill bit is rotated in preparation for parallel finishing. The tool change occurs through the TCC which houses a variety of drill types.

During the parallel finishing phase, the outline of the ‘straights’ are milled out. This outline is used to guide the cutting and laminating of the material for 4-axis milling.

The removal of dust using the air-blower once the parallel finishing is completed.

DF_Lab_SUM_2022

_CNC_Milling_3-Axis Milling result

Completion of 3-axis CNC operation The resultant geometry from the 3-axis flip mill. The geometries are held into the stock material using bridges.

Removal of holding material to release stock. The MDF bed dimensions were designed to be over-sized. This was to accomodate the variety of timber dimensions post dressing.

The removal of location pins. The 10mm pins were 3D printed through the HP machine. These were used instead of steel pins to prevent damage if there was a collision with the drill bit.

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_CNC_Milling_3-Axis Milling Inconsistencies

Milling inconsistencies and inaccuracies. There were several instances where milling accuracies were compromised. Most instances were caused by these factors: a) Excessively dense nesting. b) Milling geometries nested too closely to the edge of stock material. c) Inaccurate stock dimension inputted into tool path. d) Inconsistencies within the milling material. e) Toolpath curve incompatible with the diameter of drill bit.

Here, the dimensions of the stock material is inputted inaccurately into the toolpath. This resulted in the omission of bridges, detaching the geometries from the stock.

If the geometries are unexpectedly detached from the stock, or if the milling material experiences significant vibrations, the toolpath becomes inconsistent.

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_CNC_Milling_3-Axis Chisselling out geometries

Detaching geometries from stock material The bridges which were securing the milled geometries were removed using a chissel.

The underside of the material stock. You can spot the bridges which connect the milled geometry to the stock.

Once the geometries were isolated, each piece was labelled and annotated to allow for accurate orientation of parts.

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_CNC_Milling_Tolerances Part tolerances and alignment issues

Although milling tolerances may seem minor when observed individually, they create significant alignment issues when accounted cumulatively.

Inaccurate alignment of parts increases the risk of blockages and interferences within the internal channel. This decreases the viability of an internal liquid circulation system.

Alignment issues accumulate at part-to-part junctions. This effect is amplified due to the intricate geometry of the junction detail.

0.00mm of tolerance

0.1mm of tolerance

0.2mm of tolerance

Machining tolerances Several different tolerances were tested and evaluated throughout the prototyping stage. The evaluation showed that smaller tolerances (0.0mm) caused difficulties when aligning parts, wheras large tolerances (0.2mm) created loose part-to-part connections. A goldilocks zone was found around 0.1mm tolerance which allowed for both tight tolerances and ease of assembly. DF_Lab_SUM_2022

_Machining_Straights Mitre Saw

Stock segmentation using the Mitre Saw After the removal of the milled geometries, the remaining timber was prepared for lamination. The laminated pieces would later be milled using the 4-axis CNC router to obtain the ‘straights’. The timber segments required for lamination were outlined during the 3-axis flipmill to accelerate the segmentation process. 74

A Mitre saw was used since it is suitable for cutting across end grain. The cuts were guided by the ‘outlines’ which were milled with the CNC router.

This process segmented the timber into the lengths of ‘straights’. Each segment was labelled and prepared for trimming.

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_Machining_Straights Bandsaw

Stock trimming using the Band Saw After the segmentation of the timber, the band saw was used to trim down the segments into boxes. These boxes would later be laminated to create a stock large enough to accomodate ‘straights’.

A band saw was used since it is suitable for cutting along the grain. The cuts followed the outlines which were milled with the CNC router.

This process trimmed off the irregular offcuts and resulted in ‘boxes’. These boxes provided suitable flat surfaces for clamping.

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_Manual_Routing Digital planning

S26-27

1. Before Lamination

S26-27

2. Mark out segmentation

S26-27

3. Saw to segment

Planning for segmentation After segmenting the box pieces for the ‘straights’, 2 of the pieces - ‘Manual straights’ (S26-27 & S2-7) were isolated for manual operations. The Manual straights were measured then reproduced digitally in Rhino. The centre lines of the box pieces were checked if it corresponded to the centre lines of the ‘straights’. A revised centre-line was drawn. This line would guide the Band Saw operation in the workshop.

S26-

4. Mark ou

ent

S26-27

4. Mark out router channel

S26-27

5. Laminate pieces

S26-27

6. Lathe and measure/annotate

Planning for Lamination Lamination was also planned digitally. The box pieces were segmented using the revised centre-line. The centre-line was used to create a guide line for the table router. Although this process would have benefited from ‘scanning techniques’, in response to the tight project schedule, a tolerance of 3mm was used instead for the Band Saw operation and the table router.

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_Manual_Routing Digital planning

79.35

42.19

36.28

31.07

79.35 S2-7

36.28

42.00

18.00 18.00

21.00

42.19 S26-27

Annotations in preparation for the manual operations The digital plans and information were transferred to actual timber. The plan was also printed out to prevent tired Michael from making mistakes.

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_Preparing_Straights

Final segmentation and routing of straights Once the box pieces were obtained, they were layed out over a workbench. All the pieces were labelled and paired up in preparation for laminating. All straight pieces were designed to have a 12mm channel running through their centre line to accomodate the water tube. Most pieces had the channel routed out during the CNC flipmill operation. However, a couple pieces (S26-27) were ommitted from this process to reduce milling time. Therefore, the 12mm channels were routed manually within the workshop. Plank C2 was omitted from the CNC milling operation entirely. Therefore the box pieces had to be achieved manually using the workshop tools. The dimensions for the pieces were annotated using a rule. The pieces were then created through similar methods as priviously mentioned. For the select few pieces, the 12mm channels were created through the router table. This essentially reproduced the same effect as the CNC operation.

The required box geometries for plank C2 were marked out to guide the trimming operations using the Mitre Saw and Band Saw.

The locations of the 12mm channels were marked out to guide the milling operations using the table router.

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_Channeling_Straights Router Table

The annotations of Manual straights. The lines depict the path for the table router, and the direction of routing.

The router operation was conducted in increments. The router bit was extruded 6mm above the table for the first pass, then 12mm for the second pass.

The incremental routing minimised the risk of the inaccuracies. This risk was especially high due to the density and hardness of Spotted Gum.

The result of the router table. This accuracy is the fruits of my digital labour.

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_Preparing_for_Lamination

The S2-7 piece after it has been manually operated on. This piece had to be operated more carefully since there was only 2mm gap between the milling geometry and the stock.

All pieces with the internal channel layed out over a workbench. All pieces are paired up in preparation for the lamination. All pieces are labelled to reduce risk of mistakes.

S2-7 and S26-27 layer out inside-up to check for inconsistencies on the lamination surface.

All surface inconsistencies are flattened using a chissel or sand paper. This is to create a consistent laminating surface and increase glueing strength.

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Laminating_Straights

Once a flat laminating surface is achieved, polyurethane glue is applied across the entire surface.

Minimum amount of glue is used, just enough to cover the entire flat surface, to prevent excessive expansion of polyurethane glue.

Once pieces have been applied with glue, they are clamped on top of a covered work bench. The lamination process takes around 20-24 hours.

The geometries were laminated so that the internal channels would run without misalignment or interruptions.

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_Woodturning

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

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_WEEK_02_B Draw

The ‘draw’ phase of week 2 was concerned with the reinterpretation of the initial design proposal. The structural and geometric logic of Tree 1 was analysed. This involved the investigation of the fabrication script and its logics. Furthermore, the functional potential for the project was questioned; is the geometry of the initial branching structure approporiate for its misting function? What happens if we assign alternative functions to the project? The location and site engagement was reconsidered. The structure’s interaction with the benches and circulation around the site was a major factor. Furthermore, the ergonomics of the structure was investigated. Once the design variables were identified and understood, a preliminary structural/geometric algorithm was developed to allow for quick iterations of design outcomes. This type of computational variability was utilised throughout the later phases of the project.

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_Computational_Flowchart

Input Curve Network Curve Network A Curve Network B Curve Network C Curve Network D

Curve Network E

Initial variables

Curve Network F Curve Network G Curve Network H Curve Network I Curve Network J Curve Network K

Network Analysis

Planarity Operations

Segmentation

Ends Function

Segmentation crv 1 Segmentation crv 2 Segmentation crv 3 Segmentation crv 4

Segmentation crv 5 Segmentation crv 6

Lighting System

Channel Operations

Segmentation crv 7

Misting System

Final Geometry

Shading system

Segmentation crv 8 Segmentation crv 9 Segmentation crv 10 Segmentation crv 11

Digital Variability Variability is the primary strength of computational design. Currently, the project suffers from the lack of variability. Using an algorithmic workflow, the project could become more flexible in terms of functionality, form and fabrication.

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_Planarity _Planarity_and_Aggregation_Logic Current logic

Plane

cr 1.2 .1

crv

1.3

crv 1

Part Planarity The current geometry boils down to a simple logic/rule - the vector components of every node operate on a shared plane.

crv

3.2

Plane B

crv 2.1

cr 1.2

crv 2

Plane

Plan

crv 3.1

crv

1.3

crv 1

crv 4.1

crv

4.2

Pla

Planarity change Following the logic of individual planarity, the translation into 3D volume occurs with the planarity changes between neighboring parts. This planarity change occurs at the shared component between 2 parts.

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_Site _Exploration_of_Structure Connective branch/Arch

Exploration of form on site Initially, an arch like structure was considered. The structure would span between two opposite benches and create a over-head frame which would also serve as a gateway into msd.

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_New_Curve_Network _Network_Curves Connective branch/Arch

100

Curve logic The proposed structure follows the same spatial logic as tree 1. All components of individual part are restricted to a shared plane. The changes of planarity occurs at the component that is shared between two parts.

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101

_New_Brep _Boundary_Brep Connective branch/Arch

102

Brep logic The preliminary brep was created as a simple volumetric outcome of a multipipe component in grasshopper. The brep would serve as the guide geometry for segmentation and fabrication.

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_New_Segmentation _Planarity_Operations Connective branch/Arch

104

Segmentation logic The segmentation of the structure also borrows similar logics from Tree 1. The overall brep is segmented into nodes, straights and ends. Each part utilizes the same joint system as Tree 1. The structural integrity would rely on the existence of loops throughout the structure.

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_New_Internal_Detail _Detail Interconnected node system

Internal Curve Network One of the potential fabrication risk that was outlined for Tree 1 is the internal sprinkler network. It was predicted that the internal network could experience blockages and misalignment.

106

Reinforcing the network To resolve the risk of blockages within the internal sprinkler network, a continuous network of 12.6mm steel tubes was suggested. These tubes would be connected using 3D printed nodes. The pipes would provide a secure channel for the sprinkler network to travel through.

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_Detail _New_External_Detail Joinery logic and function

New Joint system A revised joint detail was suggested as an alternative. The new system would adopt a cutting geometry which would serve both aesthetic and structural/assembly purpose. The more pronounced middle pocket of the new cutting geometry would guide the assembly.

108

Lighting An alternative function for the structure was proposed. The ‘ends’ could be used as light sources. This alternative function would utilize a similar internal network of supply lines to make the system feasible.

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110

_WEEK_03_A Build (+ Draw)

The ‘BUILD’ phase of week 3 was focused on the evaluation and progression of the milled geometries. So far, the CNC router had produced all ‘nodes’ and ‘ends’. There were several issues with the milled results which had significant implications on the structure, assembly and the aesthetics of the final structure. A number of milled geometries had tolerance issues and milling inaccuracies. This was coupled with the fact that various components of the same ‘part’ were produced across different milling material. The differing density, colour and dimensions of the milling material amplified the tolerances and inaccuracies of the CNC router. As a result, the precise alignment of multiple components were often difficult. There were general ‘roughness’ to the CNC mill geometries. This was since the density of the toolpath was relatively low. Although this decision significantly reduced the milling time, the surface finish of the resultant geometries were quite rough. To overcome this, there was an additional process of sanding to create a smooth surface finish. There was also a process of chisseling the edges. The bevelled edges increased the fitting tolerance between neighboring parts. Once the roughness problem had been resolved, the components were glued together using polyurethane. The components were clamped together using makeshift jigs and rubber bands.

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_Preparing_Nodes

Completion of 3-axis CNC operation All the components for ‘nodes’ were milled out and layed out over a workbench. Each piece was identified and labelled in preparation for assembly and glueing.

112

All parts were dry fitted to test the alignment and tolerance of joints. More extreme cases of misalignments were identified and marked for future references.

All components of one ‘nodes’ piece was grouped. All intersections were labelled to ensure correct assembly of parts.

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_Preparing_Nodes

The extreme cases of misalignments were identified and evaluated to devise a mitigation strategy. The excess geometry was marked out using a pencil.

The excess geometry was piled away. The progress of the piling was progressively checked to prevent excessive subration of geometry.

114

A drowel was used to speed up subtraction process.

The components of each part was test fitted to track the progress of the subtraction process.

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_Preparing_Nodes

The node component straight after it has been milled and chisseled out from the milling material. The edges of the component has excess material.

The excess material around the edges were removed using a chisel and drowel. This process allowed the components to fit more tightly.

116

The joint segment of each component also had excess material around the edges. This excess material would decrease the accuracy of part-to-part assembly.

Similar process was used to remove excess material from the joint segment.

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_Laminating_Nodes

Preparation for glueing Once all components of each part had been test fitted, they were layed out over a covered workbench in prepartion for glueing. The alignment of all components were compared with the digital model before the glueing began.

118

Polyurethane glue was applied at all component-to-component edge joint.

It was important to prevent excessive use of glue. Polyurethane glue expands as it drys. Although the strength of the glue is good, the increase in volume compromises alignment.

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_Laminating_Nodes

Once all joint edges have been applied with glue, all the components are assembled into a single part.

All nodes are comprised of 6 individual pieces. The alignment of all components are guided by the 5mm steel pin dowels.

120

The assembled ‘nodes’ piece after it has been applied with glue.

Once the glueing process is complete, the individual node pieces are clamped and stabalized using rubber bands.

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121

_Laminating_Nodes

Clamping A bespoke clamping and stabilzation strategy had to be devised for individual node assembly. Rubber bands were used due to their flexibility and strength.

122

Clamps were used to provide additional stabilisation force. The clamps were applied at all the component edges to increases accuracy for later stages of fabrication.

All glued assemblies are stored away to dry and cure for 20-24 hours. Once all glueing operations were complete, all parts were transported inside the workshop.

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123

_Laminating_Nodes

Glue clean-up Polyurethane glue experiences rapid expansion in volume. Due to the strength of the glue, the expansion does not impact the structural integrity of the assembled part. However, the increase in volume impacts the alignment of neighboring parts significantly.

124

To reduce the expansion of glue, excess glue is removed with a cloth before it starts to set.

Once the excess glue had been removed, the parts were ready to be stored away.

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125

_Preparing_Ends

Completion of 3-axis CNC operation Since our group decided to fabricate the ‘ends’ pieces using 3-axis flip milling, we were able to obtain our ‘ends’ pieces much faster than the other groups. This decision was made to reduce the impact of delays on installing the 4-axis rotor. Once the process of assembling the nodes was complete, the workflow had been established for the assembly of the ‘ends’ pieces. An identical process was applied to ensure geometric consistency and workflow efficiency. This was also a chance to test fit tenons into the tenon pockets.

126

Refinment of tenon The most imporant aspect of the ‘ends’ pieces were their tenons. The excess material around tenon corners were removed using a chisel and pile. Each tenon and tenon pocket pair was tested for alignment.

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127

_Laminating_Ends

Preparation for glueing The assembly of the tenons followed a similar logic to the nodes; each side of the ‘ends’ piece was installed with a dowel pocket. The steel pin dowels were used to guide the alignment of the component pieces.

128

The flat sides were applied with polyeurethane glue for lamination.

The components were assembled and stabalised using strands of rubber bands.

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130

_WEEK_03_B (Build +) Draw

The DRAW phase of week 3 was dedicated to creating a design/fabrication proposal for a secondary structure. In devising the second structure, the group considered various aspects of the initial tree that were unsuccessful or inefficient. These aspects were adopted as flagposts that guided the secondary structure. These aspects include: a) material inefficiencies b) lack of structural/spatial variability c) the complexity of individual parts d) the excessive number of individual parts and segmentation These inefficiencies were evaluated and a potential solution was implemented into the secondary structure. The group focused on ideas which were simple to fabricated, materially efficient, and spatially variable. We borrowed aspects of computational design that celebrated ‘complexity’ produced by underlying simplicity.

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_Material_Logic Diagrams by Jack M Zhang

132

40.00

140.00

40.00

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_Material_Logic Diagrams by Jack M Zhang

40.00

140.00

134

140.00

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_Material_Logic Diagrams by Jack M Zhang

136

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_Material_Logic Diagrams by Jack M Zhang

138

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_Material_Logic Diagrams by Jack M Zhang

140

40.00

140.00

40.00

140.00

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gles _Base_Angles _Geometric_Logic Base angles

120.00°

.00

120

0°

.0 20

.00

120

.00

120

.00

120 142

120.00°

0°

.0 20

47 9. 10

7°

4 9.

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_Geometric_Logic _Variable_Lengths

Variable lengths

Decreasing part count One of the strategies used to reduce the number of parts was to elliminate the need for ‘straights’. The existence of ‘straights’ in Tree 1 was a source of various bottle-necking and alignment issues.

144

0.0

500.00

300

.00

Variability through geometric simplicity To replace the ‘straights’ parts, each vector would have a variable length. The simple geometric logic of the nodes allow each vector to be manipulated easily without affecting the logic of the overall system.

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145

_Geometric_Logic _Fractals_and_Side_Joints Fractals and side joints

Edge-to-edge connection within parts Because of the repetitive logic of the base geometric shape, the parts can be expanded using fractal logic. This allows individual components to have variable thickness. The increased thickness could allow a particular member to act as a structural column or footing.

146

Edge-to-edge connection between parts The aggregation logic could also utilize this edge-to-edge connection. This would allow for an extra dimension for creating variation within the structure. Furthermore, this type of connection would provide greater structural stability than an end-to-end connection.

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147

_Offcuts _Geometric_Logic Offcuts

Use of offcuts The offcuts carry a complimentary angle which are compatible with the main geometry in interesting ways. A potential use for the offcuts would be to use them as a laminating surface for end-to-end connections.

148

Offcuts to reinforce end-to-end connections End-to-end connections are typically much weaker than edge-to-edge. This type of connection could be improved by utilizing the offcuts as additionally glueing surface. The offcuts would act as edge-to-edge and provide structual support.

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149

_Geometric_Logic Planarity change

_Planarity_Change

150

3 opportunities for planarity change Due to the simplicity of the proposed geometry, the opportunity for planarity changes are limited. The changes occur at the 3 specific angles of the base geometric shape. However, variability could be increased using side connections and length variability.

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151

_Geometric_Logic Loops

_Loops

109.47°

11°

. 102

109.47°

° .11

102

° 1

152

. 09

120.00

11°

. 102

Loops loops loops Since the base nodes are constricted to specific angles (109.47 degrees), there is an opportunity to create loops by utilizing an additional part. The part would have an angle of 102.11 which is complimentary to 109.47.

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_Site_Conditions _Site_Conditions

Site benches We identified the most suitable benches to be used on site as above. These benches were sitting opposite to the proposed location of Tree 1. Furthermore, these benches were closest to the water supply system on site.

154

Eastern cluster of benches chosen as main site location. The benches received morning sun, and were clear of existing trees. Also, they had close proximity to water supply.

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155

_Footings _Footings

Footings between the two site benches There were 3 major footing components to the structure. The footings were located between the two main benches that were identified previously. The location of the footings would later allow the structure to interact with both benches effectively.

156

The footings were located behind and between benches A,B, and C. This allowed the structure to develop an envelope over the benches.

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157

_Main_Spine _Main_Spine

Looping logic applied for structure There was a main structural network that acted as the skeleton for the structure. This main structural element was created using loops. The logic was that loops were effective structural elements. The angle and positioning of loops were considered to allow greater area coverage.

158

The main structural spine consists of interconnected ‘loops’. The loops whilst increasing stability, also provide departure points for secondary branches and ends.

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159

_Target_Sphere _Target_Sphere

Providing coverage for two main benches The objective of the structure was to provide a over-head coverage for the two target benches on site. The coverage would be provided by the main structural loops and the protruding ‘ends’.

160

When developing the canopy, the objective was to create a semienclosure around Benches A, and B. This would create a targeted area for misting, lighting, and shading effect.

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161

_End_Conditions _End_Conditions

Coverage with ‘ends’ pieces The ‘ends’ pieces were strategically positioned to provide ample over-head coverage over the two target benches. The ‘ends’ pieces would also be equiped with sprinkler nozzels which would activate the evaporative cooling.

162

The canopy structure exist outside of the bounding box of the two benches. This prevents the structure from interfering with the benches’ primary function.

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_Renders

164

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_Renders

166

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168

_WEEK_03_C Prototyping

Week 3 saw an additional phase of ‘prototyping’ where the group produced a series of 1:1 physical models to demonstrate the ideas outlined in our proposal for TREE 2. Scrap/offcut materials were salvaged and re-used in creating these prototypes to minimise our material footprint. The things investigated during this prototyping stage are: a) the workflow of producing the proposed geometries b) material and production efficiencies c) aesthetic value and consistencies d) difficulties in fabrication e) areas that introduce human error and inconsistencies f) approporiate tools and production methods All these were discussed with the other students who were part of the DF_LAB.

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169

_Prototyping

Acquiring the material for fabrication Various offcuts and scrap materials were salvaged around the machine workshop to create a prototype for the proposed design. It was important to create 1:1 part prototypes to identify the strenghts and weaknesses of the proposed part.

170

The salvaged materials were cut into appropriate dimensions using the table saw and band saw.

The sloped angles of the base geometry was created using a table saw. The angle of the blade was adjusted and measured using a magnetic level tool.

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171

_Prototyping_edge-to-edge

Testing the potential of dominos The prototyping phase allowed us to speculate various ideas to increase the structural integrity of individual parts. Once of the ideas suggested was to use dominos to provide greater end-to-end connection strength between neighboring parts.

172

The part was able to be assembled with tight tolerances since the angle of the table saw blade was kept consistent between each component.

Various types of timber was tested throughout the prototyping stage. The proposed fabrication workflow seemed compatible with other hardwoods.

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173

_Prototyping_Lamination

The assembly logic of the prototype followed a similar logic to the components of Tree 1.

Edge-to-edge lamination was used as the assembly technique. due to the consistent angles across all components, the surface area for the lamination was maximised.

174

The consistent angles across all components also allowed the lamination process to be conducted relatively quickly.

The piece once all components are assembled.

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_Prototyping_Lamination

The lamination process was stabalised using rubber bands.

176

Opportunity for a jig We realised that the standardised geometry of the components could enable jigs to increase the production effeciency and speed. We speculated that a lamination jig could eliminate the waste of rubber bands and provide greater stabalisation during setting.

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177

_Prototyping_Jigs

The prototyping phase also saw the fabrication of various types of jigs. One of the jigs created was used for providing a specific and drilling angle.

The ‘drilling jig’ was created using a triangular offcut. A series of groves were constructed using a table saw to lock the geometries onto the jig during the drilling process.

178

Drilling jig Due to the shared angles across all components, the drilling angles were also consistent. Only 1 drilling jig had to be created to provide support for all drilling operations.

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179

_Prototyping_part-to-part

Dowel pocket A perpendicular dowel pocket was required for end-to-end connections. This drilling operation was enabled through the use of the drilling jig.

180

The pocket was fabricated using a table drill.

Again, the consistency of angles across components allowed the alignment of each component to be conducted efficiently.

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181

Laminating_Straights

The drilling jig and the prototype pieces

182

The assembled prototype node

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183

184

_WEEK_04_A Build (+ Draw)

The BUILD phase of week 4 prioritsed the post-processing of glued parts from the previous week. The excess surface glue and clamping apparatuses were removed. There was a secondary phase of surface sanding to create a more smooth surface and to increase consistency between all milled parts. There was minimal progress with the milling of ‘straights’ since the installation of the 4-axis rotor was postponed. There was a series of problem solving conducted throughout week 4. These problems were primarily concerned with decreasing the risk for the 4-axis milling. The remaining workshop access hours were utilized in assisting other groups within DF_LAB to catch up to where our group was.

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185

Laminating_Straights

186

Completion nodes lamination The laminated ‘nodes’ were layed out over a workbench to examine the effects of polyurethane glue on the structural integrity and alignment of all parts.

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187

_Removing_Excess_Glue

Post-processing of nodes All excess glue on the part surface was removed. Big clumps formed around the componentto-component joints. These were removed using a chisel.

188

Less significant lumps of dried glue were removed by shaving it off.

Glue lumps formed around tenon pockets were identified and removed completely to prevent alignment issues.

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189

_Sanding_Nodes

The condition of the node after the preliminary removal of glue.

All remaining surface glue residue and inconsistencies were removed using a rotary sander.

190

Smaller attachments were used to remove surface imperfections around tighter angles.

The surface condition after the initial pass of sanding operations.

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191

_Post_Processing_Ends

The laminated ‘ends’ pieces were subjected similar surface imperfections. The glue lumps were removed using similar techniques utilized on the ‘nodes’ pieces.

192

Smoothing out ‘ends’ pieces The minor surface imperfections were removed using a rotary sander.

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193

_Problem_Solving Knots in S2-7

There were significant knots on the surface of S2-7 which could seriously impact the structural strength and aesthetic consistency of the milled outcome.

The volume of timber impacted by the knot was removed using a band saw.

194

The band saw passes were conducted in small increments to minimise the wastage of material.

The gradual removal of knots between the band saw passes.

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195

_Lathing_Straights

The laminated ‘boxes’ for the straights were trimmed using the lathe.

The lathe required a continuous sharpening and maintaining of the hand tool.

196

Removing excess material with the lathe Excess corner materials of the laminated ‘boxes’ for the straights were removed with the lathe. This would significantly reduce milling time during the 4-axis CNC operations.

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197

Trimming_Straights

An alternative technique in removing the excess material was to use the table saw.

By angling the table saw blade, the corner material of the laminated ‘boxes’ could be removed swiftly.

198

The final shape of the trimmed ‘boxes’ This technique of using the table saw achieved the same purpose as using the lathe. However, this technique proved to be more efficient and accurate.

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199

Lathing_Straights

The boxes after trimming the corners.

It was difficult to align the rotation pin to the central axis of the geometry.

200

The lathe was used to create a circular pocket at the end of the boxes. This pocket would allow the boxes to be held more consistently by the 4-axis CNC rotation pin.

The final shape of the laminated ‘boxes’ for straights.

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201

_Problem_Solving Faulty lamination

Some laminated pieces were splitting. These pieces were opened up completely with a chisel.

The flat faces of the pieces were flattened using the planar.

202

The flat faces would provide a more consistent glueing surface for the lamination.

The internal channels were also extended using the router table.

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203

4-axis_Milling

The initial orientation of the 4-axis CNC milling. The technique is similar to 3-axis flip-milling except that the operator gains greater control over the rotation of the geometry.

The 4-axis CNC milling overcomes the limitation of the 3-axis flip milling when it comes to milling out ‘undercuts’.

204

Since the 4-axis rotar had only been installed recently, there were various tolerancing issues which had to be addressed throughout the milling process.

Excess saw dust was removed using the air gun.

DF_Lab_SUM_2022

205

206

Y-Node

Steel pins for alignment

Floating tenon

T-Node (female)

Floating tenon for planarity change

T-Node (female)

Floating tenon

T-Node (female)

_WEEK_04_B (Build +) Draw

Following the design proposals made in Week 3, a new fabrication geometry and logic was developed. The DRAW phase of week 4 was informed by my analysis and evaluation of the structure proposed by group D. Several inefficiencies and risks were identified. In response, potential solutions and improvements were implemented into a revised design. The several aspects which were considered include a) ease of assembly b) minimisation of parts c) minimisation of 4-axis milling d) improving material efficiencies e) increasing aesthetic consistencies The revised design was presented to the class and discussed for further improvements.

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207

_Initial_Proposal

Original brep and curve network The original structure was created whilst prioritising geometric and aesthetic qualities.

208

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209

_Old_Node_Logic _Node_Logic_a

210

_Node_Logic_b

Inefficient component angles The structure utilizes nodes with acute angles. This angle introduces segments of the nodes which would occupy significant volume of the milling material.

DF_Lab_SUM_2022

211

_Revised_Curve_Network

Geometry with fabrication consideration The revised structure constricts the angle of components between -45 & 45 degrees to increase consitency in fabrication.

212

DF_Lab_SUM_2022

213

_New_Node_Logic

214

DF_Lab_SUM_2022

215

_New_Fabrication_Detail _Fabrication_Detail

216

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217

_New_Fabrication_Detail _Fabrication_Detail

218

DF_Lab_SUM_2022

219

_New_Node_Detail

_T_Node_Detail

New T-node detail

220

_Y_Node_Detail

New Y-node detail

DF_Lab_SUM_2022

221

_New_Nesting _Preliminary_Nesting

Preliminary nesting to assess feasibility

222

DF_Lab_SUM_2022

223

224

_WEEK_05_A Build (+ Draw)

The BUILD phase of week 5 saw the finalisation of the ‘nodes’. This process included the application of epoxy resin to fill the gaps in the geometries. An additional process of sanding was conducted to remove all surface imperfections. Week 5 also saw the production of ‘straights’ which had been halted due to delays in installing the 4-axis CNC rotor. However, due to the difficulties in calibrating the 4-axis rotor, the geometries produced by the 4-axis CNC were victims of several fabrication issues. These issues include: a) misaligned planarity during milling b) inaccurate location of tenons c) milling blowouts d) rough finish quality These issues were outlined and resolved through manual operations.

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225

_Epoxy_Resin

Completion of 3-axis CNC operation hmm

226

Bridges are removed using a chisel and hammer.

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227

_Problem_Solving Tenon blowout in S26-27

Completion of 3-axis CNC operation hmm

228

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

229

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

230

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

231

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

232

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

233

234

Sprinkler system

Sprin kler syste

Sprinkler system

_WEEK_05_B (Build +) Draw

The DRAW phase of week 5 focused on developing the part designs for the secondary structure. The ideas discussed in week 4 were evaluated and implemented into the revised part design. A set of detailed structural diagrams were produced in preparation for engineer evaluation of the structural integrity, assembly, and safety of the structure. Additionally, alternative versions of the primary joint was considered. This was to accomodate for the intricate details of the internal sprinkler network. The speed of production was prioritised to address the shorter time-frame dedicated to producing the second structure. Various visual details were omitted to reduce milling time and risk of inaccurate assembly.

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235

_Node_Refinement Y-Node

649.88

236

467.26 DF_Lab_SUM_2022

237

_Node_Refinement Y-Node

238

DF_Lab_SUM_2022

239

_Node_Refinement Straight-cut T-Node

974.60

557.96

240

DF_Lab_SUM_2022

241

_Node_Refinement Straight-cut T-Node

242

DF_Lab_SUM_2022

243

_Node_Refinement V-cut T-Node

Grain direction

65.48

292.14

244

510.38

100.01 291.01 100.01

DF_Lab_SUM_2022

245

_Node_Refinement V-cut T-Node

Spotted gum Spotted gum

246

47.68

5mm metal shelf 5mmpegs metal shelf pegs

6.7

DF_Lab_SUM_2022

247

248

_WEEK_06_A Build (+ Draw)

The BUILD phase of week 6 saw the finalisation of all the individual parts in prepartion for collective assembly. Initially, all inaccuracies and misalignments were identified at an individual component scale. All components were isolated and its problems were addressed individually before moving on to the next. All individual components suffered from similar issues which arose from inaccurate milling. Mainly, the dimensions of the tenon pockets did not reciprocate with the matching tenons. This issue was resolved by increasing the dimensions of the tenon pockets using a chissel. Furthermore, the lengths of the tenons did not correspond to the pockets. Excess lengths were removed using a manual push saw. Once all issues were resolved at the individual component scale, neighboring parts were assessed in terms of alignment, fit and consistency. Once issues were identified, a similar process of problem solving was conducted.

DF_Lab_SUM_2022

249

_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

250

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

251

_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

252

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

253

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

254

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

255

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

256

DF_Lab_SUM_2022

257

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

258

Completion of 3-axis CNC operation hmm

DF_Lab_SUM_2022

259

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

260

Completion of 3-axis CNC operation hmm

DF_Lab_SUM_2022

261

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

262

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

263

_Problem_Solving Tenon blowout in S26-27

Completion of 3-axis CNC operation hmm

264

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

265

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

266

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

267

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

268

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

269

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

270

Completion of 3-axis CNC operation hmm

DF_Lab_SUM_2022

271

_Problem_Solving Tenon blowout in S26-27

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides of print

272

Completion of 3-axis CNC operation hmm

DF_Lab_SUM_2022

273

_Problem_Solving Tenon blowout in S26-27

Completion of 3-axis CNC operation hmm

274

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

DF_Lab_SUM_2022

275

276

_WEEK_06_B (Build +) Draw

The DRAW phase of week 6 saw further development of the internal sprinkler network of TREE 2. There were various issues identified with the initial sprinkler logic during the assembly and fabrication of Tree 1. These problems include: a) excessive complexity of sprinkler network b) lack of access into sprinkler channel for maintenance c) instancies of blockages, disturbances, and sharp angles These issues were considered and improved upon. A strategy adopted for the secondary structure was to expose the sprinkler channel at the edges of the structure. This would increase the ease of assembly, and allow the system to be maintained and repaired if problems arise. The new network was detailed and modelled in prepartion for the final presentation and subsequent milling.

DF_Lab_SUM_2022

277

_Straight_Cut_Sprinkler_Detail

1. 45

72 72

. 04

m 2m

MAIN BRANCH NODE C FEMALE

6.3

MAIN BRANCH NODE C MALE

6.3

MAIN BRANCH NODE C

278

23mm

6.3

END NOZZLE

29.8

NCH NODE C FEMALE

6.3 5

26.1

NCH NODE C MALE

INTERMEDIATE NOZZLE

SPLITTER PIPE

6.3

SPRINKLER SCHEDULE

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_V_Cut_Sprinkler_Detail

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m .0 40

MAIN BRANCH NODE A FEMALE

NCH NODE A FEMALE

7m 8. 1 2

5m 8. 1 2

MAIN BRANCH NODE B FEMALE

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_Sprinkler_Channel_Detail

m .0

.9 14

14 .9

282

m .0

MAIN BRANCH NODE D

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_Planarity_Change_Detail

.8 13

284

MAIN BRANCH NODE E

MAIN BRANCH NODE D

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End_Nozzle_Detail

286

mm 37.7 18.8 14

MAIN BRANCH NODE E

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_Sprinkler_Assembly_Sequence_A

288

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_Sprinkler_Assembly_Sequence_B

290

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_WEEK_06_C Prototyping

Week 6 saw an additional phase of prototyping. The proposed joint system for structure 2 was fabricated to demonstrate its feasibility to the presentation panel. During the prototyping phase, there were several aspects which were evaluated. These include a) the nesting strategy b) material efficiency c) structural integrity d) assembly strategy e) production workflow All the findings were discussed with the class and the presentation panel. The feedback was later implemented into the final design and digital model.

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_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides

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Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

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_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides

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Bridges are removed using a chisel and hammer.

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_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides

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Bridges are removed using a chisel and hammer.

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_WEEK_06_D Environmental Scanning

In preparation for the final presentation, a detailed site analysis was performed through a process of LiDAR Scanning. A Leica machine was used to produce an accurate pointcloud replication of the site geometry. This pointcloud was captured across several passes where each pass was conducted at different locations within the site. The pointcloud data was later used to inform the assembly and the positioning of the assembled structure.

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_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides

302

Once the print is finished, excess dust is removed using a air gun.

Bridges are removed using a chisel and hammer.

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_Post_Processing_Straights

Pass 1 of the 2-stepped milling process. The channel and pockets are created during this pass. Location pins are also created prior to flipping.

Locations pins are used between the passes to maintain accuracy between the two sides

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Bridges are removed using a chisel and hammer.

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_WEEK_07_A Build (+ Draw)

Following the completion of the subject, a roadmap to completing the assembly of Tree 1 was devised. The milling of individual parts were finalised. However, the assembly of ‘part clusters’ were incomplete. Some parts were also rushed and had to be revised to decrease the impact of inaccuracies. An assembly sequence was developed to guide the completion of Tree 1. The parts were transported onto the fabrication site and fixed onto the main structure using epoxy resin. Additional steps were taken in preparation for Tree 2 fabrication. There was a confirmation of all the available milling material. A new nesting for Tree 2 was produced from this information. Furthermore, a strategy in CNC milling was devised. Again, the speed of fabrication and assembly was prioritised. There is still (a lot) more work to be done...

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_Post_Processing_Straights

custom clamping piece to create more effective clamping angles.

308

Polyurethene glue applied to tenon.

Part to part assembly

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_Post_Processing_Straights

Clamping of one node aggregation

310

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_Post_Processing_Straights

312

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_Conclusion_(Sort_of) Reflection on past 6 weeks

The past 6 weeks was a serious process of learning. Numerous aspects of the project did not go as planned. A lot of skills and techniques were developed in problem solving. The most fufilling aspect of the project was seeing the digital artefacts being materialised through fabrication techniques. The workflow of speculating, prototyping, evaluating, and improving is definately something I will be adopting and implementing in future projects. One of the coolest subjects I have taken so far. 10/10 would recommend to a friend.

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Michael Minghi Park

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