Agenda Task 200 hours (6 weeks) – 10 pages (plus Presentation): Study and research: DIGITAL to PHYSICAL (possibly physical to digital) modelling, outcomes and processes Ways to produce from 3D digital concept to physical model. Print parts (laser cutter) + Panelling 3D print Research and describe the Modelling processes: options and alternatives. What we can do here in Victoria University? (talk to Tim Miller (SOAD-Design School)) How physical model can help in developing one’s project? How to prepare digital model to be modelled physically? Draft “First General thoughts”: 1. Digital and physical. 1.1. Physical world As we all know, people have five basic senses, that provide the inputs for perception, they are: sight (ophthalmoception), hearing (audioception), taste (gustaoception), smell (olfacoception), and touch (tactioception), 1. These are our “receivers” of all sorts of information within the space continuum, which we are able to get and analyse afterwards. Five senses, it is not that much, but it’s all we have. Hence people’s perception is limited, because while exploring any kind of phenomena or area: all we have are the inputs of very specific information: and as a result of that: our picture of the reality is totally subjective and narrow. More than that: as architects, we explore and even create a new space, new reality. It may be only a conceptual project, digital model, or a built space, nevertheless we, one way or another, form the physical reality of our habitation and future development of architecture. 1.2 Digital and Physical modelling Modern digital technologies give us a great possibility to model a virtual reality. Only with digital modeling and experimenting people actually use only one of the five senses: vision. Our brain attempts to render and experience the whole picture with all its special and material characteristics, but the result of one’s brain work will differ from the version of any other person. One of the ways to increase and diverse the sources of information, while developing a project is to physically model it. Having a physical model, we get an ability to explore our model not only visually, but also with the other senses, such as touch. We can test the physical properties of the shape that our model has: stability, balance, solidity and so on. In fact, physical model is the closest, to the actual world, source of representation of our idea. Because physical model is not virtual, it is real, it is solid, it “physically’ exists and you can not only see, but also touch, smell, and even taste it (if you want to). Somehow it is a physical model that makes people believe that it is possible to actually build the project. As a matter of fact, virtual reality and digital modeling was introduced to the world of design not long time ago, less than fifty years, to be exact. What is fifty years in comparison with thousands of years of our existence? Let us agree that, humanity has invented digital modeling just recently. However it has rapidly developed and was accepted as a primary design technique in all areas of art and engineering. As a result: digital modeling occupies a leading position among practical methods 1
http://en.wikipedia.org/wiki/Sense
of project development in architecture and design. The fact that we should take into account is that our perceptions were formed by generations and generations of people, who had never experienced digital world. From this point of view rises a reasonable question: is it prudent to limit ourselves to only one source of perception? Isn’t it rational to explore and test the concept in all the variety of possible ways? When possible: not only see but feel the thing, experience it, learn something from this experience. Even so, it is not always possible or efficient to use physical model as a test platform and in some cases, it is more effective to simulate models behavior and response on various forces digitally. Anyhow, physical model is a great way to represent any project in architecture and design. 2. Methods and techniques of physical modeling in architecture and design. 2.1. Miller and laser cutting technique Technology rapidly develops creating new methods and technologies for the architects and designers to materialize their digital models. It all started with miller and laser cutting technique, which is still broadly used in breadboarding. Laser cutting is very popular among students of architectural schools all over the world, as it is relatively simple and budget way to breadboard. It is an “easy to use” tool, while in fact it is not always the best solution. Laser cutting gives a prefabricated outcome, containing sometimes hundreds of parts, and a lot of “after work” has to be done to finish a model. Surprisingly enough in some cases it is useful, as while assembling the model one could get not only a skill to glue and organize one hundred different pieces together, but also to get utile knowledge through doing. The learning starts even before the cutting is done, as it is necessary to prepare a model for laser cutting in a proper way, which means that the whole process should be meticulously thought through: how the model can be build, what material to use, in which way do the parts come together, where are the weak parts, what is the base construction and so on… Soon students realize that material world is not a virtual one, it has its issues. In many cases, a model has to be modified, simplified or even completely remodeled, before the laser cutting will happen. There is a diverse range of ways to get really creative while making a physical model. 2.2. 2D files There are various methods techniques with which one can physically model a virtual concept. The most conventional method is to prepare and cut parts of one’s model and then assemble it manually. First of all, we assume that we already have a digital model. And in most cases it doesn’t matter which software was used for digital model creation, because there is a possibility to export or save almost any file as one of the commonly accepted 2D file types. For 2D laser and milling cutting 2: When parts or layouts are 23.5" x 35.5" or less, and are 1/4" or thinner the file types are : DXF, DWG, CDR (CorelDRAW), AI (Adobe Illustrator), SVG, PDF. The file can contain any type of curve or line. If the parts or layouts are between 23.5" x 35.5" and 35" x 49.5", or thicker than 1/4" the file types are: DXF or DWG. All curves in the file must be made up of circular arc segments (no elliptical arcs, ellipses, Bezier curves, or other arbitrary curve types, and no curves approximated by very short,
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http://www.customlasercutting.com/info/tutorials
straight line segments). This might mean that you will have to re-trace all curves by hand with many small, circular arc segments using a snapping feature and an arc-drawing tool. 2.3. 3D printing It is laudable when a student’s goal is to get knowledge and skills. Somehow these priorities are usually shifted towards producing an extraordinary design project and making it as fast and efficient as possible. Often a digital model is so complicated and curved that laser-cutting is simply not good enough. There is a solution: 3D printing. It is one of the latest, modern technologies for designers to translate a digital model to the physical world. Its concept is perfect: machine is literally printing a real physical model from a digital version. 2.4. Common RP methods 3 Stereolithography Selective laser sintering Laminated object manufacturing Fused deposition modelling Multi jet modelling ( also known as 3D printing) Selective laser melting
SLA SLS LOM FDM MJM SLM
Stereolithography Liquid epoxy resin build material. UV laser Accurate 100 micron Z step High quality surface finish achievable
Selective laser sintering Thermoplastic powder build material CO2 laser 50 micron average particle size Parts can be stacked Difficult to finish
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RP Presentation by Mike Naylon, Manufacturing Consultant, Formero Pty. Ltd.
Laminated object manufacturing Paper or thermoplastic foil build material CO2 laser 200 micron build layers Parts difficult to remove from waste material Not widely practiced
Fused deposition modelling Thermoplastic filament build material No laser 125 micron build layers Needs post build surface finishing for good appearance Weak in the Z axis
Multi jet modelling Also known as 3D printing No laser Build materials can be wax, plaster like powder, UV cured acrylates Build layer thickness down to 16 microns. Support material easily removed Wide range of material types including flexibles Can print in colour Selective laser melting 4
digitally driven, direct from sliced 3D CAD data, in layer thicknesses ranging from 20 to 100 microns that form a 2D cross section. The process then builds the part by distributing an even layer of metallic powder using a recoater, then fusing each layer in turn under a tightly controlled inert atmosphere. Once complete, the part is removed from the powder bed and undergoes heat treatment and finishing depending on the application. 5 4
http://sine.ni.com/cs/app/doc/p/id/cs-13103
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http://www.renishaw.com/en/selective-laser-melting--15240