3D PRINTED CLAY PAVILION by Mohamed Owaze Ansari

ABSTRACT

This paper aims to propose an executable pavilion as a result of informed synthesise between material fabrication and design, which rationally responds from an agent-based system to its predefined environmental challenges. For experimental purposes, attraction and repulsion behaviours of the agent-based, are primarily applied to stipulated conditions which may arise with spatial design. The site for the pavilion and predicted occupancy, dictate attraction and repulsion points for spatial design. For experiment proposes geometric interventions, which serve as phenotypes to be analysed using the structure and spatial quality, eventually leading to a pavilion that can be fabricated. The research has been conducted in three stages. Stage 01 deals with local design principles resulting from agent-based systems. Limitations that may arise during fabrication are explored to inform conditions for the global design. Stage 02 primarily deals with form generation of the global geometry. Data from the previous stage guides the geometry to eliminate or reduce the necessity of supports, resulting in phenotypes that are more well informed of fabrication, while responding to the spatial design conditions set about for the pavilion. Selection of the pavilion would be informed by computing the environmental performance (structural and shade) of phenotypes. Data from these experiments bring forth potential candidates that can be taken forward to Stage 03 of the experiment dealing with material fabrication and limits set forth, through clay extrusion using a 6 axis machine. This stage informs the design decisions taken forward from Stage 02 to be re-evaluated in terms of design or developing a hybrid system of fabrication, straying away from clay printing as the only means of fabrication.

Keywords: Agent-Based System, Robotic Fabrication, 3D Clay Printing, Milling, Form Casting.

Emergent Technologies and Design / AA school of Architecture

CONTENTS

Introduction

Stage 1 _ Agent-Based system

Stage 2 _ Design Development

Stage 3 _ Fabrication

Material Experiment

Conclusion

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INTRODUCTION

The starting point of this project was to design and develop an outdoor structure, a pavilion that could fit in a bounding box of 2x3x4 meters based on Agent-based system. The system explored in Natural Systems & Biomimetics commenced with the improvement of the computational models by abstracting the path from the agent's movement. At the same time, we should offer a clear internal space for occupation by users, while having the quality to be self-standing. The physical model should be mainly fabricated by Robotic Clay 3d-printing, through various rationalization methods and Experiments. The system should be informed simultaneously, through structural analysis, performance analysis and experimenting in diverse ways, to propose a global geometry with a constant feedback loop between advanced computational design, analysis, and fabrication strategies. Firstly, we focused on acquiring a global geometry, which is initially dictated by a given bounding box regardless of the site condition. The design strategies derived from the agent-based system was an abstraction of eusocial insects, the African Metabele Ants. We repeated processes related to the swarm behaviour of the insects based on foraging, detecting and interacting in accordance with the boundary (Bounding Box). The predicted spatial utilization with that bounding box determined the repeller points for the agent-based system to interact. The global geometry is rationalised through various stages of fabrication experiments, dictated by the limitations of fabrication setup and the material itself. Finally, the research looks into the assembly and the potential of new materials.

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STAGE

AGENT-BASED SYSTEM

To control the increase or decrease in density of the whole geometry in the system, we varied not only the number of agents but also attraction points. Similarly, to manipulate the amount of meshing in a particular plane, we rebuilt the number of curves from the given path. Varying the fitness criteria helped us to visualize the movement of the agents and the form achieved by it. We initially aimed to get individual columns that are supposed to be placed separately.

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In stage 01, we could develop four types of iterations by changing the criteria to acquire different forms of columns from the path. Fitness criteria were set up with four various factors, and we were able to get 24 prototypes through the iteration. The purpose of this stage was to find out a proper geometry as a column itself, which is self-standing. We picked four prototypes among various forms in terms of the possibility of fabrication that supposed to be built in a real by Robotic Clay 3d-printing.

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Even though a material used in between the 3D printer and Robotic Clay 3d-printing is different, we focused on a common way of printing from the basement to the top. Thus, we first printed four given prototypes at a 1:15 scale model to measure whether it is possible to fabricate though a similar way of printing. The most important factor we had to explore was the amount of support that should be required when we do a 3D printing. In general, there is no requirement for the support when we print a formal geometry, for instance, a cube form, because it can stand itself while printing. However, the geometry designed from the agent-based system was hard to print without any support. In other words, the more complex the form is, the more difficult it is to fabricate even 3D printing.

Figure 1A

Figure 1B

Figure 1 The amount of support which is required to 3d printing

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Figure 1C

Conclusion In our first trial, we printed the given four different forms through two other conditions in terms of low quality and high quality. The former way of printing took less time with less amount of material, while a vast majority of outcomes failed due to less amount of support. On the other hand, the other way of printing took a lot of time with a large amount of material, including support. Varying the infill density and layer height affected a significant role while doing 3d printing. If the basement of a printing object isn’t appropriately set at first, less infill density and large layer height have more possibility of crushing the existing object. In other words, an extruder of 3d print keeps printing, which means a failure of outcomes. We made the conclusion that our final geometry supposed to be manufactured as a complete form that has an entire structure itself for self-standing as well as acquiring spatial utilization. Therefore, Our next phase should be proceeded not only for attracting people but also as a space to achieve form from the agent-based system.

Figure 2

Figure 3

Low-quality models Printing time : 8 hours Infill Density : 7% Layer height : 0.25 mm The proportion of support : 20% - 40% Support overhang angle : 60˚ The percentage of failure : 75%

High-quality models Printing time : 32 hours Infill Density : 30% Layer height : 0.1 mm The proportion of support : 60% - 80% Support overhang angle : 60˚ The percentage of failure : 0%

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STAGE

Design Development

Site condition Our site is a courtyard where the place is located in the basement surrounded by Digital Prototyping Lab, Model Workshop, and Assembly Workshop. Many AA students are passing through the courtyard. We set our boundary into 2 x 3 meter area with 4 meter height in the center of the courtyard and divided the domain, which has 0.5 x 0.5 meter square boxes.

Figure 4 Site condition

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In stage 02, we applied attractor points and repeller points by designing a pavilion. At first, attractor points were set on the x-y plane, and repeller points were manipulated to be worked as space. Agents started from the basement were expected to form an entire geometry in response to those two different values.

Figure 5 Spatial Utilization

Figure 6 Considering attraction & repellant

Figure 7 Agent based system

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We performed manipulating agent's movements into two steps concerning varying repeller value to obtain different types of outcomes. Likewise, at stage 1, we were able to get four different kinds of curves by changing the number of curve points.

STEP 1

STEP 2

Repeller value

To attract people

As a space

Applying into the boundary box

Repeller value as a space

Agents movement

Type A

Type B

Figure 8 4 Different types of resultant curves

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Type C

Type D

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3D printing Comparison

Structure Analysis

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Conclusion According to the result of iteration, we picked two different geometry in terms of space utilization and a possible range of fabrication. That is, type A1 was our ideal model, which is designed from the agent-based system with a less procedure of rationalization. On the other hand, type D1 was generated as a more proper option for fabrication. While comparing the two geometry to choose our final form, we performed structure analysis through Karamba as well as printed by 3d printing. There was an outstanding result by comparing the outcomes of 3d printing. The first significant factor was the printing time. Even though the object named type A1 was a much smaller scale, it took more time than another object for printing. Besides, most of the time was spent on printing support. Meanwhile, the supports in type D1 were only needed where the arch form was printed because the structure of the column was enough to stand itself during printing. Another significant problem was the strength of the structure itself. When we overlapped a result from karamba with its original geometry, there was a large amount of deformation in response to a load in type A1. However, the analysis of overlapping in type D1 showed stable consequence than type A1. Thus, we concluded our final geometry by combining a top part of the former object as a canopy with a bottom part of the latter object as a stable column.

Selected Geometry

Top

Bottom

Canopy

Column (Stability)

Final Geometry

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STAGE

FABRICATION

Considerations

Constructable Bounding Box As a result of the physical conditions (ceiling, walls, obstacles)present at the fabrication site as well as the limitations of reach hardwired within the KR- 30 KuKa; The actual reach of the robot arm is far more limiting than 2100 mm radius described in the manual. Based on the set a bounding box of 900 x 900 x 600 mm would be the ideal consideration for fabrication and should be considered earlier on in the design.

Layer Height & Oﬀset Threshold Increased surface area between clay printed layers at a micro-scale of fabrication, eventually leads to strength on a macro scale. The printing tool’s nozzle diameter is a standard means to measure, and to ensure the maximum surface area the layer heights will be half the nozzle diameter ±0.5mm and the layer width will be 25% more than the nozzle diameter. To provide a stable angle of inclination on a macro scale, the layer can be safely offset to the next one from its bilateral axis by a factor of half to the nozzle diameter.

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wall

KuKa KR-30 Reach The reach of KuKa KR-30 is greatly affected not only by its angles of singularity, but also physical barriers.

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FABRICATION - EXPERIMENT 1

The geometry chosen for the test is a part of the global geometry that fits into the fabricatable limits of the KuKa KR 30. The selected geometry has complex angles of overhang projections, regions of uninterrupted surfaces and regions with undulations.

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Setup This experiment is to determine the actual size of the local geometry, as a result of which the number of elements/ sections to be assembled into the global geometry can be rationalised. The geometry in consideration is a complex surface with drastic changes in angle both in horizontal and vertical axes, with steeply angled overhangs. This is further divided in z-axis considering the nozzle thickness and the threshold of overhang to be achieved.

The images show the sequence of fabrication just before the point of collapse. Fabrication process of the local geometry revealed that physical forces acting on the clay printed layers, resulted in reconsidering the actual size of the bounding box which is far lower than the 900 x 900 x 600 mm.

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Observations

Here the fabrication is carried out with the nozzle thickness of 6 mm and a layer height of 4 mm, the programmed threshold of overlap is 3mm to achieve an angle nearing 60 degrees. Taking into account the limitations set forth by the Constructible Bounding Box of 900 x 900 x 600 mm and perceived layer height with its offset threshold; The fabrication process for this experiment was carried out on one region of the pavilion, thereby adhering to the limitations of the Bounding Box and giving rise elements that can be fabricated, which will be considered as the local geometry. The geometry can achieve a maximum height of 100 mm in as illustrated from images 1 to 9, finally reaching a certain threshold, as illustrated and collapsing shown in the sequence A to F

01 02

The images above show the sequence of inward collapse from 01 to 03. The resultant collapse helped reconsider the size of the bounding and inclusions the printing paths need to incorporate in order to achieve the maximum layer height without any infill strategies applied.

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Collapse as a result of uninterrupted surface: It can be observed that the regions lacking undulations in the printing pass are more likely to collapse.

Resultant of 01 and overreaching angle: As a result of the previous collapse in sequence of a domino effect, the layers trying to maintain stability at overarching angles are likely to fail.

Resultant collapse from 01 in the opposite direction: The resulting domino effect can change direction if there is a change in curve direction

Conclusion The result of this experiment shows undulations in the printing pass decreases the likelihood of collapse. Changes in fabrication method, specifically having more undulations in the print pass of each layer could result in larger fabricatable bounding box. The size of the local geometry ensures fewer components for assembly and reduction in fabrication time.

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FABRICATION - EXPERIMENT 2 Setup Taking into account the observations made in the previous experiment, Staggers/ ZigZags with amplitude 6mm were incorporated into the printing pass of each layer. The fabrication is carried out with the nozzle thickness of 6 mm and a layer height of 4 mm, the programmed threshold of overlap is 3mm to achieve an angle nearing 60 degrees.

Observations The geometry can achieve a maximum height of 120 mm in as illustrated from images 1 to 9, finally reaching a threshold as illustrated and collapsing shown in the sequence A to F

The images show the sequence of fabrication just before the point of collapse. Fabrication process of the local geometry revealed that physical forces acting on the clay printed layers. Due to the incorporation of stagger, the resulting geometry was higher than the previous case but still lower to the actual size of the bounding box 900 x 900 x 600 mm.

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ZigZag Pattern: Nozzle Size: 6 mm Layer Height: 3 Âą1 mm ZigZag Amplitude: 6 mm

Conclusion The result of this experiment shows that undulations in the printing pass makes a more stable structure, while solving the previous issues of collapse in sequence of a domino effect due to offset threshold and change in curve direction.But the point of collapse at 01 illustrates the need for the geometry to be changed. Changes in the final geometry, specifically rationalizing the geometry and having more undulations in the print pass of each layer could result in larger fabricatable bounding box. The size of the local geometry ensures fewer components for assembly and reduction in fabrication time.

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FABRICATION - EXPERIMENT 3 Setup This experiment is a control to the previous experiment, where Staggers/ ZigZags with amplitude 8 mm were incorporated into the printing pass of each layer. The fabrication is carried out with the nozzle thickness of 8 mm and a layer height of 6 mm, the programmed threshold of loverlap is 6mm to achieve an angle nearing 60 degrees.

Observations The geometry can achieve a maximum height of 160 mm in as illustrated from images 1 to 9, finally teaching it's threshold as illustrated and collapsing shown in the sequence A to F

The images show the sequence of fabrication just before the point of collapse. Fabrication process of the local geometry revealed that physical forces acting on the clay printed layers. Due to the incorporation of stagger, the resulting geometry was higher than the previous case but still lower to the actual size of the bounding box 900 x 900 x 600 mm.

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ZigZag Pattern: Nozzle Size: 8 mm Layer Height: 5 Âą1 mm ZigZag Amplitude: 6 mm

02 01

0101

02 01 01

Conclusion The result of this experiment shows that undulations in the printing pass makes a more stable structure, unlike the previous scenario the increased layer height brings about new issues of weight. The points of collapse at 01 and 02 illustrate the the ideal fabricating conditions can be found in Experiment 2.

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RATIONALIZING GLOBAL GEOMETRY Initial Global Geometry The geometry is a resultant iteration selected of many from the agent based algorithm, where the complex surfaces of the mesh taper outward from the base of the column and forming concave and convex overhanging surfaces at random intervals with regions of random thickness at varying intervals. The geometry when split into local geometry on account of the fabricatable limits of the KuKa - KR 30 setup .i.e. 900 x 900 x 600 mm presented its challenges in translation to a fabricatable outcome, therefore, altered the local geometry itself.

Rationalisation Process Based on the outcomes from Experiments 1 to 3, the global geometry with the inclusion of a zigzag print pass demanded changes to the geometry itself. The transformation logic applied was meant to change the column base tapering illustrated as shown in figure A, then eliminating any concave /convex overhangs along the column as illustrated in figure B, and finally tapering inwards with a wider column base as illustrated in figure C to provide added stability to the column, which intern should make a more stable global geometry. The second conclusion from Experiments 1 to 3, redefined the fabrication bounding box to 900 x 900 x 300 mm from its original 900 x 900 x 600 mm.

Volume: 145400 cubic meters

Initial Global Geometry

Geometry with complex surfaces tapering outward from the column base and forming concave and convex overhangs at random intervals with regions of random thickness at varying intervals 26

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Isolated Region

Region of the geometry within the fabricatable limits of the KuKa - KR 30 setup .i.e. 900 x 900 x 600 mm. This region is isolated as embodiment of complexity for the local geometry

The section from the original geometry requires a transformation logic applied to make the structure more stable: Figure A: Original geometry tapering outward from the column base. Section

Figure B: Eliminating any concave /convex overhangs along the column Figure C: Transformed geometry tapering inward from the column base. Transformation Logic

Conclusion The Transformed Global geometry based on the transformation logic informs the design decisions taken forward from Stage 02 to be re-evaluated in terms of design. The form is well informed by the limitations of fabrication as inferred from Experiments 1 to 3 and as a result of the transformation has a smaller volume 93511 cubic meters when compared to its original volume of 145400 cubic meters. This ensures that there is less material being utilized for fabrication, and in addition to the transformation logic would make the structure more stable. Finally, the addition of infill to the printing strategy would enable the local geometry to withstand the assembly process in sequences of 300 mm height.

Volume: 93511 cubic meters

Transformed Global Geometry

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INFILL STRATEGY

+ Rationalised Geometry

= Karamba Analysis

Infill Reference

The fabrication limit set about from the previous experiments enables us to produce individual units of maximum dimensions 900 x 900 x 600 mm. In order to incorporate the loading, each local geometry will incur while being assembled into the larger column, it is required to reinforce the clay print with infill between the inner and outer curves. The outer curves are translated from the Rationalised Geometry, while the inner curves are referenced from its Kamaba Deflection exaggerated by 50%.

Fitting Curve:

Extended Curve:

Looping Curve:

Area requiring infill

Proposed Infill

Actual Infill

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The images show the sequence of fabrication by order of assembly. Where A would be the column base and the remaining sequence from B to H will be assembled above it. The fabricated units incorporate the staggered path and will have a height of 300mm.

The digital model of the tool path was an assembly of curves and the thickness of the printed curves were not estimated With the decreasing distance between the inner curve and outer curve, the proximity between the supporting curves increased. This non-estimated proximity of printed curves let to material dragging, thus leading to gaps between the infill and Outer Curve as shown in 01 Therefore the following Correction Strategies are explored:

Extended Curve:

The ifill curve extended by half of the nozzle thickness towards the outerwall, will correct the printing and compensate for the gaps that may occur during fabrication.

Looping Curve:

The strategy is similar to the Extended Curve strategy, but due to the complexity of programming such a curve, the previous was used for fabrication.

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FABRICATION

Local Geometry Scale 1 : 2

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Scale : 1 : 2 Computational Model : 25 curves Tool Path Sequence :

Outer Curve

Infill Curve

Inner Curve

Features :

Zig Zag Tool Path

Karamba Based Infill

Overhang angle ~ 60Â°

The images show the sequence of fabrication process illustrated from A to F. The fabrication process of the local geometry incorporated the zigzag tool path, Karamba Based Infill and large overhang.

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ASSEMBLY

The assembly process is through stacking the printed local geometries with infill sequencing from 08 to 01. The inner curves of the print pass are moreover linear in the Z direction and help transfer load vertically. The infill curves not only help the inner curves in the translation of the load but also support the outer curves in supporting axonometric loads from not only the canopy but also self -

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Local Geometry Scale 1 : 2

weight. The assembly also demands a joining member running through the members during assembly, to ensure the local geometries are firmly secured in position when loaded. The components are all fabricated in 1:2 scale, therefore in actual scale will have a height of 300 mm. The approximate weight of the assembled column will be 14 kilograms when fabricated 1:1 scale.

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FORM CASTING

Karamba Analysis

Local Geometry

Regions with Deflection Range from 0.097mm to 0.173 mm have overhang values lesser than our tested threshold of 90Â° to 60. Therefore we explored a hybrid system partly clay printed when within the threshold overhang and form cast when exceeded. The negatives of the milling process were used to create hollow regions within the form cast reducing the weight by 25%.

Hollow Regions / Weight Reduction Milled Foam

Volume :8 liters

Milling Strategy

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Scale 1 : 2

A B C D E F

Milling Strategy

A B C D E F Weight: 5.8 Kilograms

Form Casted Local Geometry Scale 1 : 2

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Scale 1 : 2

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Scale 1 : 10

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FABRICATION DEFECTS & LIMITATIONS Initial Preparation When working with clay the actual printing involves a tedious amount of preparation, such as ensuring a consistent and homogenous mixture of clay in order to avoid air bubbles, filling the clay into the extruder while packing the material densely into the tube and running a dry run of the program to ensure the program runs well. The actual clay print will vary from the digital one due to accumulating errors from the preparation of clay or the real-life forces acting (like gravity and friction between material) on the physical model and should be considered as a tolerance.

Inconsistency in Material Deposition Air bubbles within the extruder tube is an element, despite careful preparation for a consistent mixture, cannot be completely eliminated. These air bubbles not only randomise the flow rate of the material extrusion but also damage the print itself. As a matter of safety and control, KuKa was manually operated. This was beneficial as air pressure, starting and stopping point of printing and speed of extrusion could be controlled, as they were constantly changing during fabrication. Manual control of KuKa run speed was beneficial in correcting inconsistent layer thickness to a certain extent.

Weight of the Canopy The volume of the transformed global geometry is 95300 cubic meters of which ~30000 cubic meters is the canopy. At 1:2 scale the fabricated column is 14 kilograms and the hollowed form cast is 5.8 kilograms. Despite the fabrication of the considered the weight of the canopy no tests were done to reassure the assumption.

Joinery The design process is constantly informed by the fabrication limitations of the 900 x 900 x 300 mm in actual scale. The 1:2 scale fabrication has local geometries with heights of 150 mm, which are stacked over each other and wooden dowels play the role of holding the column pieces on position. These local geometries when assembled, the layers do not match. This is due to higher pressure being released when the pneumatic valve is initiated during the print, before normalising much later. Thus, during assembly of the column, it is observed that the intersections have bulges. Joinery between column and form cast is a region that needs exploration. This is because the fabrication type and the masses of the objects differ, thus posing a challenge.

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Material Experiment According to the fabrication defects & limitations, we experimented to explore a better possibility in terms of material mixture. There are three main parameters in response to the amount of shrinkage, weight concerning volume, and strength about the load. We were able to find out an interesting result by mixing clay with a large amount of silicon that has less shrinkage with the least weight. Moreover, only the mixture showed a bending ability rather than a break.

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CONCLUSION The research aims to design a pavilion informed by the fabrication limitations observed during additive manufacturing. The design process is based on informed decisions made to rationalise the output from our agent-based system on the grounds of geometric and physical limitations stumbled upon through each stage, and the fabrication experiments carried out in support of those decisions. The process eventually led us to a crossroads of choosing between two pavilions - one solely could be executed through additive manufacturing with clay alone and another which is a hybrid system, partly clay printed and partly utilizing a form cast. However, we choose the latter as it posed questions of not only the assembly and joinery but also could test the structural capacity of our column, which was designed to do so.

Rationalised Geometry for Clay Printing

Translated Geometry for Hybrid Manufacturing (Printing + Casting)

Based on the material experiments most of the cases showed similar results, thus we chose to manufacture with solely clay and water for efficiency and prevent the extruder from clogging. The most interesting observation made during the material experiments was the combination of clay and silicon, which showed negligible shrinkage, high deflection and shock resistance. This could be ideally printed as the first and last print layer of each local geometry to prevent damage during assembly, different rates of curing between fabricated parts and provide tolerance for the global geometry when subjected to the environment. The research carried out has a scope to be further detailed and studied under several domains. Further Explorations: ● 3D printing with angled layers, as compared to the traditional Z axis. ● Computer Vision to regulate extrusion quantity and quality. ● Infill patterns regulated by the overhang of the geometry i.e. reinforcing more efficiently. ● Change of material in only the top and bottom layer of extrusion to better performance during assembly and prevent cracking in general. ● Joinery between different fabrication methods to be worked out for assembly.

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