MSD-RAS Final Cactus Force Research Book by Jiansong Yuan

Students: Deon Kim, Geng Liu, Yuran Liu, Claire Moriarty, Riley Studebaker, Shawn Wang, Grey Wartinger, Matthew White, Jiansong Yuan Courses contributing to this book: 802 Material Agencies: Robotics & Design Lab Instructor: Robert Stuart-Smith TA: Patrick Danahy 804 Advanced RAS Programming Instructors: Jeffrey Anderson & Jose Luis García del Castillo y López (Visiting ) 806 Experimental Matter Instructor: Nathan King 808:Scientific Research & Writing Instructor: Billie Faircloth MSD-RAS Program Director: Robert Stuart-Smith Chair of Architecture: Winka Dubbeldam ARI Robotics Lab Technician: David Forero

MSD-RAS 2020-1: Robotic Prometheus

2020-1 Spring Semester Project Book Masters of Science in Design: Robotics & Autonomous Systems (MSD-RAS) Weitzman School of Design, University of Pennsylvania

Robotic Prometheus MSD-RAS 2020-1

Matthew White Jiansong Yuan Grey Wartinger

2020-1 Spring Semester Project Book Masters of Science in Design: Robotics & Autonomous Systems (MSD-RAS) Weitzman School of Design, University of Pennsylvania Students:

Deon Kim, Geng Liu, Yuran Liu, Claire Moriarty, Riley Studebaker, Shawn Wang, Grey Wartinger, Matthew White, Jiansong Yuan

Courses contributing to this book: 802 Material Agencies: Robotics & Design Lab Instructor: Robert Stuart-Smith TA: Patrick Danahy 804 Advanced RAS Programming Instructors: Jeffrey Anderson & Jose Luis García del Castillo y López (Visiting ) 806 Experimental Matter Instructor: Nathan King 808:Scientific Research & Writing Instructor: Billie Faircloth MSD-RAS Program Director: Robert Stuart-Smith Chair of Architecture: Winka Dubbeldam Special thanks to: Advanced Research & Innovation Robotics Lab (ARI) Director: Winka Dubbeldam MSD-RAS Fall instructors; Andrew Saunders, Ezio Blasetti, Evangelos Kotsioris. Weitzman Senior Director of Operations & Planning: Karl Wellman+ Dean of Weitzman School of Design: Fritz Steiner Weitzman School Advisors & Donors who supported the construction of the ARI Robotics Lab

The Master of Science in Design: Robotics and Autonomous Systems (MSD-RAS) is a one-year, post-professional degree program in Penn’s Weitzman School of Design, Department of Architecture. The MSDRAS aims to develop novel approaches to the design, manufacture, use, and life-cycle of architecture through creative engagement with robotics, material systems, and design-computation. The degree fosters integrative design thinking, allowing students to gain skills in advanced forms of robotic fabrication, simulation, and artificial intelligence, in order to develop methods for design that harness production or live adaption as a creative opportunity. In the final semester of the program, students work in groups on a single designresearch project, developed through robotically manufactured architectural prototypes, and supported by assignments in all Spring semester courses. Projects are focused on the research and development of a novel and integrated approach to design and manufacturing that leverages newly gained knowledge in state of the art research, robotics, material fabrication, and computation. At the completion of the program each student group submits a book that documents their design-research project thesis.

Synthesizing Knowledge Across Courses The MSD-RAS curricula provides an integrated, holistic approach to learning that does not conceptually distinguish between creative and technical work, instead the program operates under the assumption that possibilities for innovation are at their best when these two activities are considered together. In the final semester of the MSD-RAS students gain knowledge and skills in a wide range of subjects including scientific research and writing, advanced computer programming (for augmented reality, simulation and real-time robot control), material and industrial processes, robot tooling, and generative computational design. This knowledge is applied within a single design-research project that is developed by student groups working across all courses. While each course is prepared and run by individual faculty who set a diverse range of assignments, the faculty collaborate to support students developing a singular project that can leverage the knowledge and skills taught in each course. Each student thesis is directed towards the development of a singular design-research project that can synthesize knowledge gained across classes. Projects are therefore multi-faceted in approach and arise from student and faculty collaborations throughout the final semester.

ARCH 804 Advanced RAS Programming (Real-time Robotics & AR/VR Programming) Instructors: Jose Luis Garcia del Castillo y Lopez and Jeffrey Anderson

Courses contributing to this thesis project book submission include:

Experimental Matter positions ceramic material systems as a vehicle for exploring applied research methodologies and investigation into the opportunities (and challenges) afforded by robotic fabrication techniques. More specifically, Experimental Matter builds knowledge in robotic and material methods of production and develops applied research for industrial robot end-of-arm tooling and I/O to enhance a material production process and facilitate new design opportunity

ARCH 802 Material Agencies: Robotics & Design Lab II (Design Studio): Instructor: Robert Stuart-Smith, TA: Patrick Danahy Design Research: Material Agencies engages with robotic fabrication and material production as generative contributors to creative design outcomes. Qualitative design character will be curated through the parallel development of custom approaches to conceiving, manipulating, and responding to matter. Material Agencies explores an architecture designed and manufactured to leverage robotic fabrication to operate as polyvalent matter, a complex heterogeneous whole that goes beyond discrete functional or aesthetic expression and operates as a bespoke solution to multiple conflicting design criteria. Working with ceramics, projects aim to integrate ornamental qualities found in early high-rise ceramic cladding by architects such as Louis Sullivan that are not economically feasible in present day mass produced building ceramics. Participants will develop an approach to design and production, operating primarily through the development of fabricated prototypes and computational, material, and robotic processes, with the aim of developing novel design affects intrinsic to material and production efficiencies.

Advanced RAS Programming explores state-of-the-art ways of robotic manipulation, with a particular emphasis on real-time control, closed-loop fabrication and human-machine interaction. Moving beyond the constraints of pre-defined, offline robotic procedures, research will focus on developing frameworks where robot actuation is reactive to materials, environments and humans, rather than pre-scripted by them. Conventional industrial forms of robot programming will be challenged, and new forms of eventbased programming will be explored, conducting to a greater degree of perceived agency in robotic behavior. ARCH 806 Experimental Matter (Materials/industrial processes/tooling) Instructor: Nathan King

ARCH 808 Scientific Research & Writing (Research & Writing for Peer-Review Paper) Instructor: Billie Faircloth This course introduces students to state-of-the-art research in robotics, materials systems, and computation through programs of research and scientific writing. It will shape a designer’s understanding of knowledge production and sharing within a thriving design research community. Students will discover how interdisciplinary research is structured, conducted, and communicated by examining research papers, applying writing methods, and talking to researchers within the field. This course will expose students to additional research opportunities in the field at a level suitable for the continuation of Ph.D. studies.

Speculative Application Scenario: The studio will develop designs that challenge established roles for architectural ceramics with a focus on facade screens, rethinking their ability to operate within the public sphere, particularly at street level. Designs will be developed digitally to the scale of approximately one typical structural bay (approx. 20m x 5m), part of which will be physically fabricated. Each student group is free to vary the site, scale and application scenario to best fit their thesis proposition.

Robotic Prometheus

MatthewAWhite

JiansongRYuan

GreyAWartinger

Robot, any automatically operated machine that replaces human effort, though it may not resemble human beings in appearance or perform functions in a humanlike manner. Moravec, H. Peter. “Robot.” Encyclopedia Britannica, February 4, 2021. https://www.britannica.com/technology/robot-technology.

Prometheus, in Greek religion, one of the Titans, the supreme trickster, and a god of fire. His intellectual side was emphasized by the apparent meaning of his name, Forethinker. In common belief he developed into a master craftsman, and in this connection he was associated with fire and the creation of mortals [from clay]. Britannica, T. Editors of Encyclopaedia. “Prometheus.” Encyclopedia Britannica, March 2, 2021. https://www.britannica.com/topic/ Prometheus-Greek-god.

Contents MSD-RAS 2020-1: Robotic Prometheus Synthesizing Knowledge Across Courses

1 4

INTRODUCTION 10 thesis statement

RESEARCH 22

urban ecology 25 29 roosting 31 workflow for building 32 multi-species cohabitation facade 32 computational tools 52 robot collision issues 57 robo-tend 62 physical tools 69 industrialized smearing tool 75 volumetric architectural ceramics: a review 80 joints 97 transportation 99 failures 103 early glazing studies 122

BUILDING PROPOSAL

142

FULL-SCALE MOCKUP

160

natural delamination study (jumping cholla) building proposal

145 145 155

delamination 163 agents 165 surface manipulated extrusions and retooling [s.m.e.a.r.] 167 structure 169

END 182

Matthew White 185 Jiansong Yuan 187 Grey Wartinger 189 references 190 acknowledgments 195

appendix 197 processes 198 properties of clay 201 basic types of clay 201 clay and clay bodies 201 clay reference guide 203 uses 205 glaze 207 firing 209 materials 215 project specific glaze brands and products 217 machines 222

INTRODUCTION

thesis statement Robotic Prometheus proposes a production alternative for architectural ceramics and facade design within the post-human future. The research engages with the plasticity of clay through robotic manufacturing behaviors to develop complex material formations at the architectural scale in order to create a rich and varied multi-species habitation whilst creating novel formal and material design effects.

context Urban development is responsible for some of the greatest local and regional extinction events, while also creating long-term threats of habitat loss for those species that do survive. With the United Nations estimating 2 billion new homes will be needed to support a growing world population, expected to reach 11.2 billion by 2100, architects and the building industry must develop methods to sustain ecological systems. At present the industry does not have sufficient means to engage with the complexity of the natural environment, which requires a post-human approach to building where design considerations are expanded to be inclusive of other species and material affects.

content Building facades pose a particular risk to bird populations. Bird strikes, collisions with reflective glazing, and loss of fly-through perching habitat through urban development, considerably impact migratory species, many of which travel directly through prominent cities such as Philadelphia on their journeys. We propose a multi-species facade. One that enables buildings to support habitation by multiple species, creating spaces for bird nesting and perching while providing human privacy and daylighting.

process Our research proposes a new design and manufacturing methodology for architectural ceramics. Typically, industrial ceramics leverage mass production methods; building facades are manufactured as extrusions or simple unitized systems relying on an optimization of dies and molds. However, a multi-species habitat requires more heterogeneity capable of supporting variations in habitat. Liquid deposit modeling of ceramics offers a means to produce a geometrically varied facade veil that can support a range of habitat conditions. Through the implementation of agent-based programming, custom robot hardware and software, and the leveraging of the plasticity of clay, our research was able to address the greater range of spatial and material conditions required by bird nesting. We developed methods for 6-axis additive and manipulative processes to enable the development of a heterogeneous facade that embodies surface texture, nesting locations, and ornament, while engaging the behavioral motions of robotics for a truly bespoke fabrication process.

Rendered Scan of Final Mockup 20

Research

RESEARCH

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Robotic Prometheus

Our process revolved around varied cross-disciplinary research threads connecting biological systems, the urban fabric, computational tools, robotic processes, and material explorations. The following pages hold a part of this greater collection of findings and results.

Research

urban ecology

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Robotic Prometheus

An early driver for polyvalence within our design was a deep dive into understanding how a building and its facade may contribute to an urban ecology. Bird strikes, the deathly impact of building facades on the migratory passage of birds, presented themselves as an opportunity in which a bio-inspired archtecture may help.

Research Robotic Prometheus MSD-RAS 26

Northern Cardinal

American Robin

Mourning Dove

Common Yellowthroat

Blue Jay

Gray Catbird

Downy Woodpecker

Scarlet Tanager

common birds in philadelphia

Red Tail Hawk, seen on campus while transporting our piece to the kiln 27

Research MSD-RAS

Robotic Prometheus

bird strikes in urban area

One of the many birds we found dead on campus, a casualty of poor building facade design 29

Research

roosting

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Robotic Prometheus

One opportunity we found interest in was the development of a free-extrusion process which could be used to print bird roosts directly onto a larger extruded clay body.

Research

INTRODUCTION

Workflow for Building Multi-Species Cohabitation Facade Abstract

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Robotic Prometheus

Rapid expansion in urbanization is constantly shifting the ecological system both around and within the city. Human activities disturb the pattern of ecology create the distinction between the traditional “rural” ecology and “urban” ecology. (Niemelä, 1999) The effect of such shift is highly dependent on the characteristic of individual specie, and therefore calls for highly customizable solution when it comes to creation of urban habitation. This paper proposes a case-study system that combines a computational way of modeling nesting site for the migratory birds with additive robotic manufacturing method to create bespoke façade system allowing for urban habitation creation for specific target specie. The outcome of the research would establish technique and system for mass customized façade system/ potential nesting site to be deployed to specific site within the urban ecological pattern to help restoring the urban habitat of such specie.

Urbanization and ecological preservation have always seemed to be on the two sides of the same scale. In people’s minds, better living condition of the human being usually comes at the cost of destruction of animal habitats in a detrimental way. However, with a bit more research, this perception gets a lot more complicated than usual understanding. Without a doubt, the whole ecological system can be altered dramatically by human activities. Nevertheless, such change does not necessarily come in a negative sense for all kinds of animal species. This can be proven by simply taking a stoke around the city block with sparrow chipping on the sidewalk, raccoons looking for food in the trash can. Without any intentional intervention from the human being, animals have never been absent from urban life; instead, some are thriving with increasing food and shelter place from human activities. Therefore, when it comes to creating urban habitat, careful consideration must be given to which species we provide temporary shelter for without conflicting with the existing ecology of those that are thriving already. In the case of this research, migratory birds are the target species as up to 1500 bird dies daily from bird strike in Philadelphia alone. (Kummer, Frank, 2020)

In order to “emphasizes human impact by identifying social components with connections to ecology,” a “human ecosystem model” needs to be implemented and considered to establish the correct parameter from which the habitats will be modeled from. (Niemelä, 1999) This involves three key terms of categorization: urban avoider, urban exploiter, and urban dweller, which distinguish specific categories of species that “disappear with urbanization, whereas other species invade in response to the environmental changes associated with development.”(Sandoval, Luis, 2018) To restore the ecological richness of urban area means the proposal needs to be targeted towards urban avoiders whose population decline with increasing anthropogenic impact while decrease or not affect that of urban exploiters who benefit from human activities to avoid conflict of resources. (Sandoval, Luis, 2018) Such specific customization of habitat solution needs to come from a computational model that takes into account both what the animal species is and the ecological information of the specific site to find the optimal proposal. This way, the model would combine both the parameter of scientific research of what the specific species needs and parameters from the existing result of human impact. The multi-scalar model helps with the formation of habitat at a local scale, density, and distribution of habitats at the façade scale. With this background, the research focuses on the question of the manufacturing method to realize such a proposal at scale. How could the flexibility of formal design of a façade be combined with infinite customization of potential local habitat location through additive robotic manufacture? What are the limitation and possibilities of such a manufacturing method?

2 Diagram of human activities impact on different urban ecology

3 Early bird nest + clat body blcok prototype

1 Final Prototype

Research

4 Dried cholla Cactus 5 Houdin particle physics simulation 6 2.5D vertical extrusion 6

7 6 axis support-free extrusion 8 Final result prototype render

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Robotic Prometheus

METHOD

OUTCOMES

This paper will explain in detail the research conducted that focuses on the case study of designing the urban habitat of one specific bird type(Scarlet Tanager) in the urban area of Philadelphia. This specific bird is chosen as the study type as it is commonly found in the easter forest, especially in Pennsylvania. They love staying high in the forest canopy, making them more vulnerable to the potential bird strike of high-rises in urban settings. (Audubon, 2020) Scarlet Tanager is perfect as a case study for its size and nesting habitat. Typical Scarlet Tanager is a tiny bird for about 6 to 7 inches that nest typically nest 20-30’ above ground (All About Birds, 2021). Their eggs are about 0.6 - 0.7 inches wide and 0.8 - 1.1 inches long, with 3 to 5 eggs per clutch. This provides a potential habitat size of 5 inches by 3.5 inches at about two to four stories high up, given the average ceiling height of 9 feet.

manufacturing makes the proposal feasible, providing flexibility in formal design and infinite customization ability. First, the base form was manufacture using the typical 2.5D LDM manufacture method. This process is similar to the now commercialized 3d printing process but with more customization from consideration of the specific clay property as limiting parameters for printing speed/print width and draft angle. After the base form is created, potential nests will be manufactured on the side wall using the 6-axis extrusion method without the need for additional support material. This is enabled by the specific material property of 3d print clay. Both the viscosity and density of the material affect how much overhang it can achieve without delaminating from its base clay body. This also determines the print speed and pitch angle of the end effector of the robotic arm during the 6-axis printing process.

At façade scale, taking inspiration from the formal characteristic of a dried cactus, the design focuses on the delamination from stress loading to create apertures and potential nesting location to be sifted through using nesting parameters of Scarlet Tanagers such as nesting size, height, and density. Such a model is then imported into particle physics simulation to generate a point cloud of angulating mesh surface informed by the aperture/nest positions. This modeling sequence creates a generative model workflow that incorporates information on local nest creation for the birds at the architectural scale.

The prototype is manufactured in clay in favor of its flexibility of formation, additional bonding time frame, and transformative material quality after kiln firing. Clay is extruded using the WASP clay extruder as the end effector on the ABB 4600 robotic arm, which adds additional operation freedom on the X, Y, Z axis to the usual precision of the delta type 3d printing machine. The material used for the study is clay designed specifically for 3d printing. The Sio-2 PRAI 3D clay has property optimized for 3D printing with a firing range of Cone 6-10, 22% water content, and 8.5% shrinkage rate. Its characteristics offer excellent behavior during drying and firing(Manufacturer of Ceramic Bodies and Clays for Modelling, 2021). All these material properties directly affect the print parameter and eventually affect the result of the physical prototypes.

Under these conditions, a manufacturing method capable of such high customization is needed to efficiently and accurately realize the proposal from the multi-scalar computational model. 6-axis Robotic additive

This project proposes a 3’ by 4’ prototype as proof of concept. Both 2.5 axis clay extrusion as façade scale base form and 6 axis operation as local nest scale are explored in the chunk model. The chunk is subsequently divided into 9 roughly same size blocks of 12” by 16” in order to cope with kiln firing size limitation that is available at the moment. All blocks are extruded at around 20-22mm wall thickness to achieve the strength for them being hollow structure without additional internal webbing, which allows for post-tensioning using GFRT caps and steel rod along the Z-axis.

The whole prototype is a proof of concept for manufacturing both the façade geometry from the generative model and habitat geometry from the computation data, demonstrating the techniques for automated fabrication of complex, parameter-driven form-finding procedures for human-made urban habitat space for migratory birds. This process allows for flexibility and customization that operates at multiple scales from the output of multiple stakeholders who will harmoniously share the project.

Each block of the chunk model takes around 5 hours of extrusion at 9 m/s motor speed of the WASP end effector with around 50 degree/s– 60 degree/s moving speed of the robotic arm adjusted according to print width fluctuation due to clay inconsistency. Total extrusion time is approximately 60 hours considering clay tank swap out time. Each block takes about 6 bags of standard Sio-2 clay, and each weighs around 11 pounds. This adds up to around 60 pounds of total weight per block minus the loss of moisture content during the drying process. The whole project weight around 580 pounds, taking into consideration of all the connection hardware. Two types of bird nests are explored in the prototype, side opening and bottom opening. Both are formed on the side of a block with 6-axis extrusion and 6-axis smearing to help to blend them onto the clay body. Extrusion width is the same as 2.5d extrusion at around 20mm width at pitch angle within 30 degrees from the normal of the base surface depending on the curvature and shape of the block. 35

Research Robotic Prometheus

CONCLUSION Both the computational workflow and prototype manufacturing process discussed in the paper demonstrate an autonomous way of modeling and manufacturing a multi-species urban habitat to help restore the balance in urban ecology at an architectural scale. Such workflow uses both inputs from scientific research data on the urban ecological pattern, migratory species ID, species nesting habit, and design decision from a designer in one workflow to combine and try mitigating long-lasting conflict between the need of human and species of other kinds. Scientificdata-driven designs are essential in creating urban habitat for the correct target species without bias from human judgment. On the other manufacturing makes the proposal feasible, providing flexibility in formal design and infinite customization ability. First, the base form was manufacture using the typical 2.5D LDM manufacture method. This process is similar to the now commercialized 3d printing process but with more customization from consideration of the specific clay property as limiting parameters for printing speed/print width and draft angle. After the base form is created, potential nests will be manufactured on the side wall using the 6-axis extrusion method without the need for additional support material. This is enabled by the specific material property of 3d print clay. Both the viscosity and density of the material affect how much overhang it can achieve without delaminating from its base clay body. This also determines the print speed and pitch angle of the end effector of the robotic arm during the 6-axis printing process. The prototype is manufactured in clay in favor of its flexibility of formation, additional bonding time frame, and transformative material quality after kiln firing. Clay is extruded using the WASP clay extruder as the end effector on the ABB 4600 robotic arm, which adds additional operation freedom on the X, Y, Z axis to the usual precision of the delta type 3d printing machine. The material used for the study is clay designed specifically for 3d printing. The Sio-2 PRAI 3D clay has property optimized for 3D printing with a firing range of Cone 6-10, 22% water content, and 8.5% shrinkage rate. Its characteristics offer excellent behavior during drying and firing(Manufacturer of Ceramic Bodies and Clays for Modelling, 2021). All these material properties directly affect the print parameter and eventually affect the result of the physical prototypes.

9 Overall prototype elevation 10 Side-open nest volume 11 Close-up robotic operation texture

MSD-RAS

IMAGE CREDITS

Figure 2: © Encyclopedia of Ecology, 2008 Figure 4: © N/A. http://sailpanache.com/wp-content/uploads/2012/01/ DSCN1043.jpg 37

Research

computational tools

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Robotic Prometheus

In order to enable the development of complex ceramic forms and ornament we had to research and create complex computational tools. What follows are visual representations of design algorithms, generative studies into material placement, and robot control processes which opened up new avenues of exploration within the confines of our lab environment.

topological shape optimization

We implemented a tso modeling system as a generative design means to explore how material might be organized along a laminar surface.

Research

agent catalogue _ 01

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Robotic Prometheus

Early development of robot path control was initiated through agent steering behaviors based on Craig Reynolds seminal work. These agent paths begin to develop a tailorable and responsive robotic pathing towards the development of a new architectural ornament.

48 49

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Robotic Prometheus Research

Research Robotic Prometheus MSD-RAS

Close-up of agent path extrusions printed on a clay surface

Agent paths extruded on an mdf board

Research

agent catalogue _ 02

MSD-RAS

Robotic Prometheus

Behaviors were then applied to these initial paths in a secondary process, further modifying and developing the paths.

Research Robotic Prometheus MSD-RAS

Close-up of agent path behaviors smeared on a clay surface

Agent path behaviors smeared over agent path extrusions

Research

robot collision issues

Standard CAD/CAM simulation only goes so far in preparing the robot path development for 6-axis extrusion

MSD-RAS

Robotic Prometheus

Robot collisions with the pre-existing geometry was a primary issue as we began to develop a multistep robotic process. As the image at right shows, the robot peripheral equipment was often a burden in developing 6-Axis extrusion and manipulation paths. Although simulation and collision management was used within our path-planning framework, we wanted to begin research into how a human interface might allow for more adept control of individual robot orientations within a larger operation.

Research MSD-RAS

Robotic Prometheus

To overcome these challenges, we proposed a real-time monitoring system which would enable a robot operator to isolate potential upcoming collisions points along a robot path and then send those areas to a human mediator for manipulation. Using a VR rig, the mediator could then manipulate a localized set of points dynamically, unencumbered from the 2-Dimensional and limited perspective of a standard CAD/CAM system.

60 61

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Robotic Prometheus Research

Research

INTRODUCTION 6-Axis industrial robotic arms pose a continual challenge for machine path planning. The very nature of their axial flexibility, and the increasing complexity of their use in the fabrication of designed geometries, lends the simulation environment of 6-axis robotic arms to be ever evolving and variable. Within our own research towards a multi-robotic process for bespoke ceramic geometry, countless hours were spent within typical robotic simulation environments attempting to manage collisions with the pre-existing geometry, the environment, and the robotic arm. Although it became evident that extending the Stop-Gap Collaboration approach was necessary (Johns et al. 2019) in which we could bridge the technical gaps of the path-planning methods we had at our disposal through human spatial intuition, the technology for human-mediated robotic path-manipulation needed to be developed. Our research outlines one method for the human manipulation of pre-defined robotic toolpaths through the use of a VR environment and a computer to machine interface for the development of complex robotic toolpaths.

Robo-Tend Human Articulation of Robotic Motion ABSTRACT

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Robotic Prometheus

6-Axis industrial robotic arms are often considered to be largely anthropomorphic machines; their motions can be understood through an embodiment of the machine itself. When attempting to explain or understand robotic motions, users will use their own bodies, arms, and hands to mimic rotations and plane orientations. However, the development and simulation of robotic path-planning is still an un-embodied process, often relying on computer aided design (CAD), computer aided manufacturing (CAM) software interfaces, and computer screens to develop and simulate the robot processes. This paper presents an offline method for editing and simulating robot motion paths in a virtual reality (VR) environment using hand control to directly edit robot target planes. This approach is especially relevant in the modification of complex one-off robotic programs commonly used in advanced robotic fabrication of unique objects.

Machine and robotic path-planning is a rapidly expanding and nuanced field within the realms of fabrication, automation, and robotics. Specifically within fabrication, path-planning optimization becomes increasingly more complex when the geometry in question is a freeform surface (Elber, Cohen 1993), or the machine contains five or more axis (Jun et al. 2003). Historically, when fabrication and automation are interlinked, path-planning optimization is celebrated within the narrow focus of time of production optimization (Chiou, Lee 2002). More recently however, in relation to robotics, machining time based approaches have shifted focus towards developing more robust means of robotic path-planning targeted towards geometric complexity through robotic kinematic reachability and orientation nuance (Ma et al. 2020). Furthermore, significant technological gains have been made in the optimization of collision-free path-planning tools (Huang et al. 2018) which enable highly complex robot pathing to be developed algorithmically. There are various robot control softwares available for designers using CAD software. Examples of these tools include Robots (Soler 2016), HAL Robotics (Schwartz 2013), and KukaPRC(Barumann and BrellÇokcan 2011). Although these tools enable designers to quickly generate geometry specific robot code for a proprietary machine language such as Rapid for ABB or UR Script for Universal Robots, the tools are limited in their human interface, being restricted to the interfaces provided by the CAD/CAM softwares themselves, and require significant human time to ensure robot paths are collision free for safe machine operation. More significantly, the movement of the robot is limited by the ability for the designer to manipulate the orientation of target planes. The standard CAD/CAM workflow is an inherently un-embodied experience; it separates the vision and tactility of the human designer from the physical machine process. Yet, if it is evident that an embodied experience is valuable within the design process (Gengnagel et al. 2018), where is the embodied principle being applied to robotic fabrication? More often than not, research has focused on bringing the human embodiment into a real-time environment with robotic fabrication. Interactive fabrication has been developed as a means to leverage the perception of the human as an extension to robotic fabrication (Mueller et al. 2018), or to dissolve the need for the CAD/CAM workflow entirely by developing a human/ robot collaborative interface (Peng et al. 2019). Additionally, augmented reality (AR) environments are being developed to create personal fabrication (Weichel et al. 2014) and more topically within architectural fabrication, AR is showing promise as a tool to provide the tabular and geometric strengths of computers to the human laborer (Jahn et al. 2019). Although many of these methods provide human mediation of robotic processes within various moments of a geometry’s fabrication, they do not leverage human intuition for spatial configuration and time to assist robots during the fabrication process. Moreover, the previewing of robotic simulations is still largely confined to a 2-Dimensional viewing plane (the computer monitor). Our research builds upon the VR and AR robot collaboration platform Robo-Stim (Johns et al. 2019) using Unity and C#, in combination with the computational framework for real-time robot programming and control Robot Ex Machina (Garcia del Castillo y López 2019) to extend the Stop-Gap Collaborative approach so that the designer is given direct embodied control of robotic toolpaths to facilitate the development of robust and complex robotic toolpaths. 63

Research

METHODS

Target Push

Software

The first development in our process was the implementation of a back-end function which utilized Ex Machina’s bridge capabilities as a web-socket platform to pass information between softwares. Although we understand a custom web-socket structure could be developed to push data between Rhino/ Grasshopper and Unity, and in many cases already has been developed (Horikawa 2017), our process removes the need for this additional piece of software. In Grasshopper, a list of target planes are deconstructed into their index ID, their cartesian location, and the x, y, and z vector matrices that define their orientation. This information is packaged in Grasshopper and sent through the Ex Machina bridge as a “Message” command, and presents itself to our custom C# function within the VR environment to be parsed out again using a comma separated values method. Using a Unity plane prefab we developed for simulation purposes, the parsed data is applied to a Parent list of target planes, each with their corresponding ID and respective target positions and orientations. By assigning an ID, the user can push target information from Grasshopper at any time, and the new planes will override existing pushed planes. Target lists of up to 20,000 planes were tested with no errors.

Robotic paths providing target points and base orientations were generated with the Rhino7 3D modeling software (McNeel & Associates 2020) and its visual programming language Grasshopper. Target point locations and orientations were passed from Rhino/Grasshopper to Unity, version 2019.3.6.f1 (Unity Technologies 2019), through the Robot Ex Machina framework (Garcia del Castillo y López 2019). Using a comma separated values method written in C#. The information was parsed out from an Ex Machina message into individual target planes within a Unity VR game environment. From there, multiple C# functions were developed to extend the work of Robo-Stim (Johns et al. 2019) into a user interface for robot target orientation and path manipulation within a virtual environment. The connection between Unity and the VR headset was managed by SteamVR (Valve Corporation 2019). Once a desired robot path had been established, a button within our framework could send all of the robot target planes to RobotStudio 2020 (ABB 2020) via the Ex Machina Bridge. Hardware We used the HTC Vive Headset for VR display, with a refresh rate of 90 Hz and a 110 degree field of view. Vive Controllers allowed for human input of target plane manipulation, with the Vive Base Stations monitoring orientation of the Controllers and Headset. The trigger buttons, grip buttons, and track pads were implemented as methods to receive human input within the virtual environment. We used an ABB IRB 4600 60/2.05 both virtually in RobotStudio and physically within our lab setup to verify the virtual robot path planning results. Functions As stated, the research was focused as a means to extend the capabilities of the Robo-Stim and Ex Machina platforms towards a human VR robotic path-planning and mediating system. In such, the methods for this research were primarily developed as custom C# functions built within the Unity environment, and were implemented into trigger buttons on the Vive Controllers for human use. The functions developed can be broken down into two main categories: target push and target manipulation.

A sample of the comma separated values code sent from Grasshopper to the Ex Machina Bridge through the “Message” command.

Target Manipulation

Robotic Prometheus

The second development in our process was the means of manipulating a single target plane and the effects of that manipulation on the list of targets. When the user pulls the Vive Controller trigger, left or right, the current target that is selected is identified by the code and made available for manipulation. The controller orientation, captured as a quaternion, is then remapped to the current target, and any subsequent manipulation of the controller quaternion is applied to the current target until the trigger is released. This process enables the human hand to directly influence the orientation of a single robot target plane. However, unless the user is extremely careful with their hand movements, having a single plane be largely different from its neighbors presents dangerous and often challenging kinematics to a robotic arm. Consequently, we developed a buffer system by implementing the native Spherical Linear Interpolation (SLERP) functionality within Unity to modify the neighboring planes both in the positive and negative directions along the robot target path. SLERP was chosen for its softness in quaternion interpolation, as opposed to the computationally lighter, but more rigid, Linear Interpolation (LERP). The SLERP buffer range is controlled by the user as a slider within the UI of the system, and the consequences of extending or shrinking the buffer range can be previewed in real-time as the plane objects change orientation.

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The user can be seen manipulating the Vive Controller with their index finger activating the trigger. On the screen is a flattened image of what the user is seeing, with the robot position updating in real time.

In order to understand the robotic movements while target manipulation is being executed, a series of time buttons were established within the UI of the VR environment. The robot kinematics at the current plane can be cycled through both in a step-by-step method both forward and backwards, or through a play or rewind button, animating the entire robot path. Additionally, a speed slider was provided to change how fast the kinematic animation took place. 65

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Through the methods outlined, this research is capable of pushing robot target points and plane orientations from Rhino/Grasshopper to a VR environment generated through Unity. A user wearing a VR headset and using VR controllers is able to then modify the robot path a single target plane at a time, with the modification extending across an isolated range of planes in either direction along the robot path. In our research, we found applications for these tools as a means to quickly and intuitively adapt robot paths which contained explicit robot target positions, but undeveloped orientations about that position. A pre-existing complex geometry was being post-processed with a cumbersome and large robot endeffector. Through a virtual simulation of the pre-existing geometry, robot, robot end-effector, and robot environment, we could implement the research outlined in this paper to more intuitively and adeptly develop complex robot orientations, which were otherwise exceptionally time-consuming to develop in the standard robot control systems available to designers today.

Our research exists as just a fraction of the significant work which remains to be done in the realm of StopGap Collaboration, Human in the Loop systems, and Teleo-Operation of robots. Primarily, our research is limited by its virtual and physical environments. Virtually, it exists within a combinatorial framework of Robo-Stim and Ex Machina, and as such is limited through these tools. Moreover, the process requires an accurate environmental simulation to be of use for robot collision avoidance. The functions we developed can exist as the backbone to a more robust system, but are few in number, and warrant further development to validate the physical and time cost of putting on and establishing the VR environment. Currently, only a time controller and plane manipulator exist as functions of the system. Ideally, many of the functions which exist in standard robot control systems would be available to the user within the VR environment, developing a robust pipeline for users to more completely develop robot toolpaths in VR. Additionally, our process only works for a single robot path, with path parameters only being defined at the beginning of the path. In order to develop more robust robot processes, a means of subdividing the list, managing these sub-lists, assigning robot operators (speed, acceleration, tool processes, etc.), and sending sublists of code to be implemented by the robot could all be developed. CONCLUSION

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This research opens up the gap within the standard “mouse and screen” CAD/CAM and robot planning paradigm by providing a human user the ability to express target orientations with the motion of their hands. This new system for control was established so that robot path planning can be easily given the control and adaptability of a human to better develop complex motion paths for industrial robotic arms. We believe this research takes a step towards a Stop-Gap Collaborative approach to robotic implementation, one in which human motion and robotic motion are more closely entwined, and the generation of robot paths can be an embodied experience for designers and programmers. We look forward to better developing the UI of the tools, applying these processes to an Augmented Reality environment, and enhancing the flexibility of the system at large.

The human hand and Vive controller ascribes a new target plane orientation to the robot motion path. A buffer range can be decided on through controller buttons. A still of the display as established in the VR environment. The UI interface shows the simulation control features built into the screen.

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physical tools

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The development of complex algorithmic and formal designs necessitated equally complex physical tools and production processes. Without consideration of the tooling and material limitations of our lab we would never have been able to achieve a fully developed mock-up.

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Although the simple stainless steel ball tool we used for our experiments worked plenty well at the research level, we needed to better understand what an industrialized process might look like for robotic smearing. The next few pages show how the custom end effector could have a dynamic set of features to allow for tool changing and water-pass through.

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ABB IRB 4600 Quick Changer (Master Side) Air Quick Changer Module Electric Quick Changer Module Fluid Quick Changer Module

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Axon of custom end effector, showing the various mechanical features that activate the tool, and allow for the passage of water and changing of tooling sides.

Section through the custom end effector, showing the movement of water all the way to the tool center point in order to lubricate the tip for proper clay smearing.

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Air Quick Changer Module Electric Quick Changer Module Fluid Quick Changer Module

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INTRODUCTION Considered the first human-design material, ceramics have been a part of the built environment for millennia. Earthen materials such as clay, and sand were permanently bonded under intense heat. During this process, material properties changed substantially, creating a harder, durable, and water-resistant substance. This man made material -- ceramic-- had properties similar to stone, but was easier to shape and work prior to being fired. (Bechthold, Kane and King 2015) This ease of shaping; along with advancements in both materials and manufacturing, allows ceramics to be used in a variety of fields today. Including but not limited to the chemical industry, machinery, electronics, aerospace and biomedical engineering. (Chen, et al. 2019) Within architecture and the built environment, ceramics are generally used as a surface in either the interior and exterior condition. Providing designers the opportunity to use the material in both performative and ornamental ways.

Volumetric Architectural Ceramics: A Review Liquid Deposit Modeling for volumetric architectural ceramic components. ABSTRACT

Many of the current standard practices of forming architectural ceramics require use of molds or die to create form. Requiring additional material that is not part of the final artifact. Not only impacting the project’s budget and schedule, but requiring designs to rationalize designs to a defined number of elements. By integrating digital technologies and new insights from material science, well established ceramic forming techniques could go by the wayside in lieu of additive manufacturing. Allowing for the construction of complex ceramic elements without the additional waste. This paper provides a brief overview of the current state of manufacturing architectural ceramics today. Highlighting the potential new forming technologies; particularly additive manufacturing (3D Printing) can on the future of architectural ceramics. The paper is divided into three parts. The first part provides an overview on current standard methods of forming architectural ceramics. Along with a brief overview of the current status of additive manufacturing techniques using ceramics. The second part presents current approaches of computer-controlled layer based extrusion processes at the architectural scale. The third part, the main subject of this paper, looks at the emerging process of Liquid Deposit Modeling (LDM) and introduces the potential for LDM to produce complex volumetric architectural elements without the need of secondary elements such as molds and dies. This process is informed by the properties of the clay body. The aim of the paper is to explore the potential of LDM to remove the need for custom dies and molds. Creating an opportunity for designs where no two parts are the same. In addition, this fabrication method has the potential of becoming a low-waste and ecologically sustainable construction technique for complex ceramic construction.

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Contemporary forming methods for Architectural Ceramics are material-intensive, labor-intensive, constrained to unitized systems that often result in homogeneous outcomes.. We look to the additive manufacturing technique of Liquid Deposit Modeling (LDM) to resolve the shortcomings found within current techniques of dry-pressing, extrusion, slumping, die-cutting, plastic pressing and slip casting. Particularly the reliance on die and molds that take both the resources of time and capital to create. Which are ultimately discarded after production creating additional waste. Ceramic LDM proposes an alternative of form making with the benefits in quality, customization, speed, cost and functionality. All while limiting waste by creating a near zero waste production process. of complex one-off robotic programs commonly used in advanced robotic fabrication of unique objects.

Nearly all production processes associated with architectural ceramics follow a similar sequence that includes the creation of the clay body, followed by shaping, drying, firing, post-processing, and packaging. [Bechthold, Martin, et al.] This paper will only be looking at the shaping portion of the production sequence.

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Diagram of ceramic process. From clay body to ceramic.

Diagram of a LDM extruder setup.

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ARCHITECTURAL CERAMICS Overview of current forming methods The most common production techniques for shaping architectural ceramics generally fall into two categories; “wet” and “dry”. With the terms making reference to the water content of the clay. Distinction between the terms has to do with production capacity, dimensional tolerances, types of tooling used, and part costs. “Dry” clay bodies reduce the amount of time required for the clay to move from its raw state to being bone dry or ready for firing. Typically used in the production of tiles. While “wet” clay bodies are used during the shaping of geometrically complex parts. Dry-pressing Dry-pressing; considered a “dry” process, and is typically used to create flat or slightly textured ceramic tiles where a powdered clay body with a moisture content between 3-7% is pressed under high, evenly distributed pressure in a steel mold. Due to the high tooling costs of the steel molds, dry-pressing is reserved for high production volumes and offers little opportunity for customization except for post processing after firing. Post processing can include being cut to create unique shapes. Edge grinding can be used for either ornamental shaping or to reduce dimensional tolerances. Fired tiles can also be shaped through slumping techniques during a secondary firing. (Bechthold, Kane and King 2015) Extrusion Extrusion; considered a “wet” process, uses a clay body with a moisture content of 14-22%. The clay body is forced through a vacuum chamber using a large screw system that ensures a uniform consistency and removes air pockets prior to being pushed through the shaping die. The clay body is pushed through the shaping die in a continuous manner, resulting in linear parts with a continuous cross section. Next the material is cut to length. Extruded parts typically undergo two firings. Due to the higher moisture content, extruded parts tend to exhibit high shrinkage rates than processes that begin with a clay body with a lower moisture content. Extruded parts are generally sided, where one side is considered the finish surface and one side will be hidden. In many architectural applications, shaping die is detailed in such a way that the hidden side of the finish parts contain grooves or notches that allow for easier installation. Like most ceramic components, fired extruded parts can alter through cutting or grinding to mitigate dimensional variations

Slump Forming / Slump molding Slump molding, considered a “wet” process, is when a clay body, typically created through the extrusion process is cut to size, and placed over a one-sided mold. Final dimensioning and shaping of slabs can occur prior to molding or after the clay has been placed on the mold. Typically used when large minimum radius are acceptable. Kiln-based slump molding is similar to the process, however the stock material has already been fired. The already fired part is typically scored through grinding or placed on the mold within the kiln. The second firing softens the ceramic enough to allow for plastic deformation to occur without losing its surface quality and dimensional accuracy. Typically used when small; minimum radius is required. (Bechthold, Kane and King 2015) Die-cutting Die-cutting, a process that is used in medium volume runs. Typically consists of an extruded rectangular slab that is cut to a finished shape using a vertical steel die cutting tool. Once a piece is cut, the remaining clay is fed back into the extrusion line, creating a near zero waste production process. (Bechthold, Kane and King 2015) Plastic Pressing Plastic pressing, considered a “wet” process, is when a clay body with a moisture content of 14-22% is formed using a double sided mold. A clay slug or slab is placed in the mold and formed under relatively low pressures. Due to the low mold pressures the molds can be constructed out of low cost materials such as gypsum. Like all molding processes, parts need to be designed considering proper draft angles. Along with the elimination of overhangs or undercuts. (Bechthold, Kane and King 2015) Slip Casting Slip casting is a “wet” process involving a near liquid clay slip that is poured into a plaster mold and allowed to dry. It can either be allowed to dry completely, or be left in the mold for a set amount of time. There is a direct relationship between time and wall thickness. Both varianiation of slip casting allow for the creation of complex geometries through multiple part molds. A plaster mold is used until it becomes overly saturated. Typically the molds have a use cycle of approximately 100 before they need to be replaced. In high volume production settings a series of tools are created to create replacement plaster molds. Often, the mold or die outlasts the production cycle and is stored for use at a later time. Designs need to either be thought about with a process in mind or post-rationalized to accommodate one of the techniques. Even with this in mind “A typical project will require multiple dies as well as special pieces that may be produced with a combination of extrusion, plastic pressing, or slip casting (Bechthold, Kane and King 2015).” Resulting in numerous items that will need to be discarded.

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due to shrinkage, or to allow for additional attachments or connections. Clay bodies that are formed through the extrusion process can also be used as the base stock for other forming processes where a homogenous slab or shape is desiure; such as slumping, pressing, or die-cutting. (Bechthold, Kane and King 2015)

Image of clay slip being poured into a plaster mold. Example of the slip casting process

ADDITIVE MANUFACTURING 3D Printed Ceramics In recent decades, advancements in both materials and technology have promoted ceramics within a variety of industries. Complex ceramic components that are either difficult or impossible to build using conventional manufacturing methods can now be created using the following 3D printing techniques. Powder-based fusion (SLS and SLM) ceramic 3D printing technologies mainly utilize powder beds normally containing loose ceramic particles as feedstock. The ceramic particles are bonded either by spreading liquid binders or by powder fusion using thermal energy provided by a laser beam. Slurry-based photopolymerisation (SL, DLP and TPP) ceramic 3D printing technologies generally involve liquid or semi-liquid systems dispersed with fine ceramic particles as feedstock, either in the form of inks or pastes, depending on the solid loading and viscosity of the system. The slurry content can be 3D printed by either photopolymerisation, inkjet printing or extrusion. Bulk Solid-Based 3D printing utilizes solid materials in either a sheet or filament form that is bonded together using heat. (Chen, et al. 2019).

Image of clay body after being Ram pressed. Example of the plastic pressing process. Image of clay body after being extruded through a forming die. Example of the extrusion process. https://bostonvalley.com/manufacturing/production/forming/

While these methods are effective in creating complex ceramic elements for a variety of industries. Current limitations in overall size of printed objects, print times and costs of proprietary powders and resins are 83

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3D printing of ceramics: A review

Zhangwei Chen, Ziyong Li, Junjie Li, Chengbo Liu, Changshi Lao, Yuelong Fu, Changyong Liu, Yang Li, Pei Wang, Yi He

Powder-Based

Slurry-Based Slurry-based ceramic 3D printing technologies generally involve liquid or semi-liquid systems dispersed with fine ceramic particles as feedstock, either in the form of inks or pastes, depending on the solid loading and viscosity of the system. The slurry content can either be 3D printed by either photopolymerisation, inkjet printing or extrusion.

Stereolithography (SL) A light source at a certain wave length (usually ultraviolet) is used to selectively cure a liquid surface in a vat containing mainly photopolymersiable monomer along with additives in very small amounts, particularly photo initiators. The light activated polymerisation process (i.e. liquid monomer turns into solid resin) generally proceeds point-to-line, line-to-layer, then layer-by-layer, along with the light scans on the liquid surface

Digital Light processing (DLP) Masked based SL, in which an integral image is transferred to the polymerisable liquid surface by exposing the light source through a patterned mask once only.

Inkjet printing Ceramic inks where ceramic particles are well dispersed within a liquid solvent for direct and selective deposition onto a substrate through a printhead. A solid ceramic phase can be created after proper drying and sintering of the printed materials.

Direct ink writing (DIW)

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Powder-based ceramic 3D printing technologies mainly utilize powder beds normally containing loose ceramic particles as feedstock. The ceramic particles are bonded either by spreading liquid binders or by powder fusion using thermal energy provided by a laser beam.

Three-dimensional printing (3DP)

Bulk Solid-Based 3D printing utilizes solid materials in either a sheet or filament form that is bonded together using heat.

Laminated object manufacturing (LOM) The process generally involves computer-controlled laser cutting of as-prepared thin sheets of materials into cross sections according to sliced digital CAD models and subsequent layer-wise adhesive agents to form 3D parts. Bonding and lamination between adjacent layers can accomplished by real-time heating and mechanical compression.

Ceramic inks where ceramic particles are well dispersed within a liquid solvent for direct and selective deposition onto a substrate through a printhead. A solid ceramic phase can be created after proper drying and sintering of the printed materials.

Selective laser sintering (SLS) A high-powered laser beam is used to selectively irradiate the surface of the target powder bed, The powder then heats up and sintering (i.e. interparticle fusion) takes place for bulk joining. After this, a new layer of powder is spread onto the previous surface of the next run of heating and joining. In this way, the process is repeated layer by layer until the designed 3D part is fabricated. No extra support structures have to be intentionally prepared for overhanging regions during an SLS process, as they are surrounded by the loose powder in the bed at all times.

Fused deposition modeling (FDM) In an FDM process, the material filament is continuously supplied to and heated within a moving nozzle at a temperature just above its melting point so that it can be easily extruded via the nozzle to form layers. Upon extrusion, the material solidifies immediately over the previously printed layer. Like some other 3D printing technologies, the platform then lowers so that the extrusion of the next layer can take place. Supports can be built and removed after the part is complete. For ceramic materials to be used in FDM, composite filaments are prepared by densely loading ceramic particles (up to 60 vol%) into thermoplastic binders.

Selective laser melting (SLM)

After printing, the printed ceramic part is subjected to binder removal and sintering to achieve densification.

Very similar to SLS except that it is a time-saving , one-step powder bed fusion by full melting, which uses laser sources with much higher energy densities and requires no secondary low-melting binder powders.

Olivier van Herpt ‘s delta robot work cell for LDM printing of clay bodies.

An extrusion method using a filament of a highly viscous paste (analogous to conventional inkjet printing ink) at room temperature. The deposition manifests itself as extrusion of materials through nozzles whose opening are required to be much larger than those of IJP nozzles owing to the higher viscosity of the materials used. Objects are built up by moving nozzles to directly "write" the design shape layer by layer until the part is complete. Debinding and sintering then follow so that the part is free of organics.

light source (ultraviloet)

ceramic particles contained in a liquid

3D WASPs Crane WASP extruding a natural mixture.

ICON’s 3D printer extruding a concrete mixture.

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Diagram of categories of ceramic 3D printing as outlined in 3D printing of ceramics: A review

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challenges in creating ceramics at the architectural scale. (San Fratello and Rael 2020)

3D Concrete Printing In the past decade, the 3D printing of concrete (3DCP) at the architectural scale has had tremendous growth. Originally appearing around 2010, when Dr. Behrokh Khoshnevis of the University of Southern California presented a process called Contour Crafting using a cartesian machine with a concrete extruder. Contour crafting, similar to LDM, is a construction technique that operates by extruding material in layers through a computer guided nozzle. However, in contour crafting the outer surfaces are smoothed by trowels that follow the nozzle. (Leach, et al. 2012) Since this development numerous private companies and research institutions have explored how 3DCP can address issues within the building and construction industry. Liquid Deposit Modeling Liquid Deposition Modeling (LDM) is the name of the technology that Italian delta 3D printing manufacturer WASP uses for its extruder for ceramic materials. The system was originally developed to allow for the use of functional, end-use materials like ceramics, porcelain, clay, alumina, zirconium, and other advanced ceramics. Since it has expanded to other paste-like materials such as cement mortars and mixtures based on raw earth. LDM printing follows the same rules as FDM printing with one significant difference; there is no heat used during the extrusion process. Resulting in a clay form that needs to dry prior to being kiln fired. (WASP 2016) The LDM WASP Extruder is based on a pneumatic system in which a pump sends the paste ceramic materials through a tube to a screw extruder. The combination of the pneumatic system with the screw extruder makes it possible to accurately control the flow of material. Even use retraction to interrupt deposition. Innovations also include a system which eliminates air bubbles in the mixture and an outward pressure multiplier up to 40 bar in the screw extruder. (WASP 2016)

LDM of Clay and Natural Mixtures In the spring of 2021, Bologna-based architecture studio Mario Cucinella Architects working alongside WASP completed a housing prototype out of local clay using LDM 3D printing technology named TECLA (Parks 2021). This was done using the multi-printer Crane WASP system. A modular and multilevel 3D printer that allows for multiple print heads to work collaboratively to build architectural scale works on site. The Crane WASP system is erected on site where the building volume is formed through layer-by-layer extrusion. The maximum module size is currently defined by a printing area of 50 square meters (approx. 550 sq ft). TECLA took 200 hours to print and is constructed out of 350 layers of 12mm high extrusion. With a total extrusion length of approximately 150km or 60 cubic meters of natural materials. (WASP 2021) LDM of Ceramic clay bodies Initially ceramists began to explore the advancements of LDM printing technologies at the scale of the vessel.The new developments allowed them to scale up. Creating objects at scale of humans (Herpt n.d.). The size constraint is now relative to the kiln dimensions and transportation constraints between the print bed and the kiln. Similar to the constraints of current ceramic forming methods(Boston Valley Terra Cotta n.d.). With this in mind, architectural ceramics can now be explored through LDM without the constraints of molds, dies or the requirement of repetitive pieces. Geometrical constraints are now limited to printer size, kiln size, and material properties of the clay body. Allowing for an unlimited number of different geometrical conditions to be explored in a single project. Conclusion The paper presents the current state of creating architectural ceramics and analyzes current developments within additive manufacturing. Speculating on additive manufacturing, particularly Liquid Deposit Modeling printing techniques can be leveraged to create ceramic elements at the architectural scale. The presented additive manufacturing method of Liquid Deposit Modeling, opens the door to more individualized, freeform architecture using ceramics. In addition, the forming process does not require molds or dies to create complex geometries, but instead relies on the designer to understand the constraints of both the process and the material. Resulting in building components that allow ceramics to be used in new and novel ways at the architectural scale. All while minimizing the amount of waste created during the process. 85

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transportation

We endured many challenges getting our bone-dry clay pieces to the kilns. After learning a difficult lesson, we knew we had to develop a better strategy. This is a short story in images outlining our developtments.

So we built a cart!

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We tried to carry them by hand, but they were too cumbersome

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early glazing studies

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We tested multiple glaze colors and patterns to our original extrusion and form tests from the small ABB IRB 120 Robot and the 2mm Wasp Extruder.

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We quickly learned that in order to better understand how glaze would fire, we had to work more systematically using bisque fired tiles. Tests were performed to understand the effects of: multiple layers, different glaze overlays, and application methods.

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1111 Holly Green

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A critical lesson we learned through the tile studies was that, unfortunately, the glaze fires very differently when applied to different clay bodies, and on flat surfaces vs. surfaces with extreme texture. Thankfully, we had been studying various methods of robotic extrusion at the same time and were able to quickly move to extruded clay bodies to test our glazes.

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glazed tablets

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Lastly, we glazed our various smearing tests. Here texture and metallic glazes were used to understand how heavy glazes sat inside the textures resultant from the robotic smearing operations.

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BUILDING PROPOSAL

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A building proposal was established in order to extend our research and consider the greater architectural implications of our mock-up design as we developed it. This proposal provided opportunity to push back on the mock-up with how it performed as an architectural facade system, both as an object of scale and materiality, but also at a multi-scalar level, with how ornament established itself throughout the work.

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natural delamination study (jumping cholla) The jumping cholla, a cactus with multi-scalar material organization across the body which creates both stiffness and porosity. At its core, the cholla cactus is a delaminatory structure in which external forces split linear elements away from each other.

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Multiple methods for delaminatory facades were developed and tested. Eventually, one was developped which utilized a tso as a generative model for orienting curves across a surface, grasshopper/python code distributed apertures along the curves, and houdini was used to develop a more complex surface.

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Houdini particle simulations play out to orient material along the curves and develop a delaminatory approach to volume modeling.

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The following mockup images were developed using our extensive research, with multiple robotic processes, exhibited at full-scale.

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delamination

Rectilinear grid used as the base of a typical module construction system

Influenced by the jumping cholla cactus, the vertical joints of our facade system delaminate to create apertures. With the potential to vary in scale to accommodate a variety of programmatic requirements. The geometry of the apertures are define by both material and production constraints.

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Delamination of vertical joints to create apertures

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Base geometry created through 2.D printing

Agent based modeling is used to control how surface variation is layered onto the clay body. This surface variation ties together both a formal strategy for facade ornament, as well as creating secondary voids within the facade that enable bird inhabitation.

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Edges created through the delamination process are used to guide agents

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surface manipulated extrusions and retooling [s.m.e.a.r.] Surface Manipulated Extrusions and Retooling creates a controlled blending effect between the multiple extrusion layers. This process is both an aesthetic one, and one that we propose may increase layer bonding. Base geometry created through 2.D printing

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structure Due to the requirement for the mockup to be have the ability to be re-assembled. A post-tensioned structural system was devised using HPDE spacers and threaded rods. Verticle Structure - Post Tension Rods

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Horizontal Structure - HDPE Splice plates

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Bio

Matthew White

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Matthew White is a graduate of University of Pennsylvania’s Weitzman School of Design. Where he received a Master of Science: Robotics and Autonomous Systems. He also holds a Master of Architecture from Washington University in St. Louis and a Bachelors of Fine Arts from the University of Iowa. He is currently conducting research as a Penn Praxis Design Fellow. With previous employment at a variety of design and fabrication offices including Situ Studio and UAP.

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Bio

Jiansong Yuan

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Jiansong Yuan is a graduate of University of Pennsylvania’s Weitzman School of Design where he received a degree in Master of Science: Robotics and Autonomous Systems. He also holds a degree in Bachelor of Architecture from University of Southern California. He is currently conducting research as a Penn Praxis

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Grey Wartinger

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Robotic Prometheus

Grey Wartinger is a fabricator, roboticist, computational designer, and model maker based in Jersey City, NJ. He has established three different professional robotics and fabrication facilities, led workshops, managed construction teams, and worked with designers across the globe to realize their designs; the scales of which span from individual presentation models to full-scale occupiable structures, made with a range of analog, digital, and robotic tools. He holds a Masters of Science: Robotics and Autonomous Systems from the Weitzman School of Design at the University of Pennsylvania and a B.Arch from Pratt Institute.

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References

ABB, 2020. “RobotStudio” Bechthold, Martin, Anthony Kane, and Nathan King. 2015. Ceramic Material Systems in Architecture and Interior Design. Birkhäuser. Boston Valley Terra Cotta. n.d. Forming Methods. Accessed May 11, 2021. https://bostonvalley.com/ manufacturing/production/forming/. Braumann, Johannes, and Sigrid Brell-Çokcan. 2011. “Parametric Robot Control, Integrated CAD/CAM for Architectural Design.” In Proceedings of the 31th Annual Conference of the Association for Computer Aided Design in Architecture, 242-251. Chen, Zhangwei, Ziyong Li, Junjie Li, Chengbo Liu, Changshi Lao, Yuelong Fu, Changyong Liu, Yang Li, Pei Wang, and Yi He. 2019. “3D Printing of ceramics: A Review.” Journal of European Ceramic Society 39 661687. Chiou, Chuang-Jang and Yuan-Shin Lee, 2002. “A Machining Potential Field Approach to Tool Path Generation for Multi-Axis Sculptured Surface Machining”. Computer-Aided Design 34 (5): 357-371. Elber, Gershon and Elaine Cohen, 1993. “Tool Path Generation for Freeform Surface Models” in the second ACM symposium on Solid Modeling and Applications, 1993. 419 - 428. García del Castillo y López, Jose Luis, 2019 in ACADIA 19:UBIQUITY AND AUTONOMY, 40-49 Gengnagel, Christoph, Robert Patz, and Monika Grzymala, 2019. “Bodily Design Processes in Immersive Virtual Environments” In Impact: Design With All Senses, edited by C. Gengnagel, O. Baverel, J Burry, M. Ramsgaard Thomsen, S. Weinzierl, 350-359, Berlin: DMSB 2019.

references

Herpt, Oliver van. n.d. Functional 3D Printed Ceramics. Accessed May 11, 2021. https://oliviervanherpt. com/functional-3d-printed-ceramics/. Horikawa, Junichiro, 2017. “Plugin to send Grasshopper geometry to Unity in realtime”, video. Huang, Y., Garrett, C.R. & Mueller, C.T., 2018. “Automated sequence and motion planning for robotic spatial extrusion of 3D trusses”. Construction Robotics 2: 15-39

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ICON. n.d. ICON Build’s Technology. Accessed May 11, 2021. https://www.iconbuild.com/technology.

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Jahn, Gwyllim et al., 2019. “Making in Mixed Reality”. Conference: Recalibration: On Imprecision and Infidelity Johns, Ryan Luke, Jeffrey Anderson, and Axel Killian, 2019. “Robo-Stim: Modes of Human Robot Collaboration for Design” In Impact: Design With All Senses, edited by C. Gengnagel, O. Baverel, J Burry, M. Ramsgaard Thomsen, S. Weinzierl, 671-694, Berlin: DMSB 2019. Jun, Cha-Soo, Jyungduck Cha, and Yuan-Shin Lee, 2003. “Optimizing Tool Orientations for 5-Axis Machining by Configuration-Space Search Method”. Computer-Aided Design 35 (6): 549-566. Kummer, Frank. “Up to 1,500 Birds Flew into Some of Philly’s Tallest Skyscrapers One Day Last Week. The Slaughter Shook Bird-watchers.” Https://www.inquirer.com. October 07, 2020. Accessed May 12, 2021. https://www.inquirer.com/news/birds-center-city-philadelphia-audubonoctober-2-2020-20201007.html. Leach, Neal, Anders Carlson, Behrokh Khoshnevis, and Madhu Thangavelu. 2012. “Robotic Construction by Contour Crafting: The Case of Lunar Construction vol. 10 - no. 3.” International Journal of Architectural Computing 423-438. 191

References

Li, Enjie, Sophie S. Parker, Gregory B. Pauly, John M. Randall, Brian V. Brown, and Brian S. Cohen. “An Urban Biodiversity Assessment Framework That Combines an Urban Habitat Classification Scheme and Citizen Science Data.” Frontiers. July 04, 2019. Accessed May 12, 2021. https://www.frontiersin.org/ articles/10.3389/fevo.2019.00277/full. Lloret, Ena, Amir R. Shahab, Mettler Linus, J. Robert Flatt, Fabio Gramazio, Matthias Kohler, and Silke Langenberg. 2015. “Complex concrete structures: Merging existing casting techniques with digital fabrication.” Computer-Aided Design 60 40-49. Ma, Zhao et al. 2020. “RobotSculptor: Artist-Directed Robotic Sculpting of Clay”. SCF 2020: Symposium on Computational Fabrication. “Manufacturer of Ceramic Bodies and Clays for Modelling.” Manufacturer of Ceramic Bodies and Clays for Modelling. Accessed May 12, 2021. https:// www.sio-2.com/us/prai-3d/subfamily/100. McNeel, Robert and Associates, 2020. “Rhino 7” Mueller, Stefanie et al., 2019. “FormFab: Continuous Interactive Fabrication”. In TEI ‘19: Proceedings of the Thirteenth International Conference on Tangible, Embedded, and Embodied Interaction, 315-323.

More-than-Human Design: Prosthetic Habitats for the Powerful Owl (Ninox Strenua).” Impact: Design With All Senses, 2019, 554-64. doi:10.1007/978-3-030-29829-6_43 Unity Technologies, 2019. “Unity” “Urban Habitat.” Urban Habitat - an Overview | ScienceDirect Topics. Accessed May 12, 2021. https://www.sciencedirect.com/topics/ earth-and-planetary-sciences/urban-habitat. Niemelä, J. Is there a need for a theory of urban ecology?. Urban Ecosystems 3, 57–65 (1999). https://doi.org/10.1023/A:1009595932440 Valve Corporation, 2019. “SteamVR” WASP launches the new professional clay extruder. May 22. Accessed May 11, 2021. https://www.3dwasp. com/en/wasp-launches-the-new-professional-clay-extruder/. Weichel, Christian et al., 2014. “MixFab: a mixed-reality environment for personal fabrication”. In CHI ‘14: Proceedings of the SIGCHI Conference on Human Factors in Computing Systems, 3855-3864. Yuan, Philip F., Neal Leach, and Achim Menges. 2018. Digital Fabrication. Tongji University Press Co., Ltd.

Parks, James. 2021. Dezeen - Tecla house 3D-printed from locally sourced clay. April 23. Accessed May 11, 2021. https://www.dezeen.com/2021/04/23/mario-cucinella-architects-wasp-3d-printed-housing/. Rael, Ronald, and Virginia San Fratello. 2018. Printing Architecture: Innovative Recipes for 3D Printing. New York: Princeton Architectural Press. Peng, Huaishu et al., 2018. “RoMA: Interactive Fabrication with Augmented Reality and a Robotic 3D Printer” In CHI ‘18: Proceedings of the 2018 CHI Conference on Human Factors in Computing Systems, 1-12.

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San Fratello, Virginia, and Ronald Rael. 2020. “Innovating materials for large scale additive manufacturing: Salt, soil, cement and chardonnay.” Cement and Concrete Research 134. WASP. 2021. TECLA, a 3D Printed global habitat for sustainable living. Accessed May 11, 2021. https:// www.3dwasp.com/en/3d-printed-house-tecla/.—. 2016. Sandoval, Luis “Urban Habitat Management That Could Attract Species That Otherwise Avoid Cities.” The Nature of Cities. August 13, 2018. Accessed May 12, 2021. https://www.thenatureofcities.com/2018/08/12/ urban-habitat-management-attract-species-otherwise-avoid-cities/. Soler, Vicente and Vincent Huyghe, 2016. “Robots” “Scarlet Tanager.” Audubon. March 26, 2020. Accessed May 12, 2021. https:// www.audubon.org/field-guide/bird/scarlet-tanager.

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“Scarlet Tanager Life History, All About Birds, Cornell Lab of Ornithology.” , All About Birds, Cornell Lab of Ornithology. Accessed May 12, 2021. https:// www.allaboutbirds.org/guide/Scarlet_Tanager/lifehistory.

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Schwartz, Thibault. 2013. “HAL: Extension of a Visual Programming Language to Support Teaching and Research on Robotics Applied to Construction.” In Robotic Fabrication in Architecture, Art, and Design, 92-101. Vienna: Springer Roudavski, Stanislav, and Dan Parker. “Modelling Workflows for 193

Acknowledgments

acknowledgments

The research presented in this paper was partially made possible by the efforts of the ARI Lab at the University of Pennsylvania Stuart Weitzman School of Design, and the Masters of Science in Design Robotics and Autonomous Systems program. Additional gratitude to the amazing staff at the University of Pennsylvania, specifically, Karl Wellman, Mark Harper, Willie Udell, and the House-Keeping crew who tried their best to take care of our endless mess. Lastly, we dedicate this book to all of our fallen, feathered friends. We wish we could have done you more justice, and hope architects and designers world-wide will strive to make your world a better one.

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We would like to thank all of our tremendous professors who guided us through this research endeavor. Special shout-out to Patrick Danahy and his tireless efforts. We would also like to thank David Forero for holding it down in the lab all year long.

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APPENDIX

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processes

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clay and clay bodies CLAY is the product of the breakdown of the earth’s rocky surface (primarily feldspar rock) through the actions of wind, water and temperature. These small particles are typically washed down from their formation sites in the mountains and are deposited in lakes, rivers and streams, collecting into deposits known as clay. This process is an ongoing geological system and continues to this day, which is why clay is found in vast quantities all over the planet. CLAY BODIES are blends of clay minerals and elements that produce specific results when manipulated and treated in various ways. These custom blends of clay minerals are the modern clay bodies and can be tailored to produce a wide range of colors, textures, strength and temperature ranges.

properties of clay TEMPERATURE: Different clay bodies “mature” at different temperatures. By “mature” we mean fired to the temperature for which they were formulated. In general terms, the higher a clay body is designed to fire, the more it will be come water resistant. WORKABILITY: The workability of a clay generally refers to how easy it is to shape without problems. If problems do occur, a workable clay would allow you do fix those problems and continue with out crumbling or collapsing. COLOR: The color of a clay is affected by the materials used in the blending process. For example, a clay body that has a lot of iron in it will be red like Terra cotta flower pots.

basic types of clay PORCELAIN: A high-firing fine-grained white clay body that mature to a durable, strong, vitreous ceramic. It is usually pure white because of its high kaolin content and lack of other ingredients like iron that can change the color and properties. STONEWARE: A mid- or high-firing coarse-grained clay body that can be anywhere between a buff color to gray to dark brown, because of varying levels of iron and other ‘impurities’. It is incredibly durable after firing, with little water absorption (vitreous). EARTHENWARE: A low-firing fine-grained clay body that is typically grey, orange, or red in color both in the raw state and after firing. This highly porous clay will remain highly absorbent even after firing and will melt at porcelain and stoneware temperatures. absorption (vitreous).

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https://www.theceramicshop.com/content/425/Clay-Reference-Guide/

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clay reference guide

High Fire Stoneware Clay (Cone 10) Earthen- colored stoneware clays produce durable ware and most will react favorably to the manipulation of air, gas and smoke in reduction firing. These clays have good plasticity and will perform well in both wheel throwing and hand building methods. High Fire White Stoneware Clays (Cone 10) High fire white stoneware clays also have good plasticity and contain a small amount of sand to increase their strength and workability, making them slightly open when fired. These clays have become very popular because of the clean canvas they provide for a myriad of glaze colors. Some iron speckling can occur but for the most part, glaze colors are not affected. Midrange Stoneware Clays (Cone 4-6) Midrange stoneware clays are similar to cone 10 clays in their workability and represent potential savings in lower firing costs. The lower firing temperature and oxidation atmosphere allow for the use of a large palette of ceramic stains and cause less warping of the ware. Porcelain Clay (Cone 6-11) Porcelains are most commonly known for their whiteness and for having some degree of translucency. They are pure and vitreous which gives them their inherent glaze fit quality and unparalleled hardness and durability. Low Fire Earthenware Clay (Cone 06-04) Low fire clay tends to be either reddish or white in color. These clays tend to be more porous, making them ideal clays for planters. Glazing is required to create a waterproof surface. When fired, these clays are nonvitreous and have low shrinkage. Low fire dinnerware does not take extremely hot temperatures well, and repeated exposure to such temperatures can result in cracking and crazing. Paper Clays Paper Clay is a combination of paper pulp and clay that has the benefit of strength that aids in the safe transport of work and reduces breakage of larger pieces. Water transporting fibers make slip joined dryto-dry additions successful and also aid to reduce warping and cracking of tiles, slabs and during force drying. We offer Miller/Laguna Max’s Cone 5 Paper Clay (Cone 04-10), BMix w/ Grog Paper Clay (Cone 04-10), and Bob’s Tile & Sculpture Clay (Cone 04-6). Paper clays are made in small batches and can be special ordered through The Ceramic Shop. Non Firing Clay These Clays are designed not to be put in the kiln and are intended for sculpture or decoration, not dinnerware. Non firing clay comes in self hardening (or air dry) that dry to be super stiff without a kiln firing. Modeling Clays keep their softness and can be reused over and over again for mold making or kids projects. Recommended Self Hardening Clays: Miller/Laguna: Wed, Standard Clay 910, Amaco: Stonex. Modeling Clays: Amaco Artone Venus, Modeling Clay, Kids Modeling Clay: Amaco Plasticlay, Super Dough, Cloudclay, Mudmagic

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https://skutt.com/skutt-resources/education/ceramics-101/

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uses

Dinnerware/ Tableware Functional ware is considered objects like bowls or mugs that will be holding foods or liquids. There are a wide variety of different types of clays ranging from dark stoneware to smooth white porcelain or slightly grogged textured clays that are suitable as long as they have a low water absorption rate. For stoneware clays look for a claybody with less than 3% absorbtion and for porcelain look for less than 1%. Recommended clays for Cone 10: Miller/Laguna Clays BMix10, 750, 900. Standard Clays: 153, 259, 306, 181, 182. For Cone 5-6: Miller/Laguna Clays Bmix5, 40, 45, 50, 55, 60, 65. Standard Clays: 112, 240, 266, 553, 563, 153, 259, 306, 181, 182. Ovenware Many stoneware clays will work well for ovenware, but clays that can handle the thermal shock of low to high temperatures work best. Cone 5 stonewares tend to be less susceptible to thermal shock but all ovenware made of stoneware should be heated and cooled gradually. Selecting a glaze that fits well and can also withstand the heating and cooling changes is necessary and may take some testing to figure out what works best. Recommended clays for Cone 10 include: Miller/Laguna 750, 900. Standard Clays: 153, 259. Cone 5-6: Miller/Laguna Clays 60, 70, 45. Standard Clays 112, 153, 259. Floor & Outdoor Tile Tiles should be made from a strong, durable clay to withstand wear and tear and changes in temperature. Commercial producers employ special production techniques to increase the durability and provide lower shrinkage. You’ll want to select a tile with grog for floor tiles and clays with low absorption rates (2% or less) for outdoor tiles. Glazing outdoor tiles and using a cover sealant will help protect your tiles from the thermal shock of changing weather. Recommended clays for floor tile include Cone 10: Miller/Laguna Clays 900, 900. Standard Clays 108. Cone 5-6: Laguna/Miller 45, 60. Standard Clays 108, 420, 547. Low Fire Cone 06-04: Laguna/ Miller Clays 26, Standard Clays 104. For outdoor tiles use 900, 80, 90, 65, 66 547, or 26. Sculpture Clays Sculpture claybodies contain significant amounts of sand and grog in various mesh sizes and are formulated for a low rate of shrinkage. These clays are designed to accommodate large handbuilt, wheel thrown or sculpted projects. Recommended clays for Cone 10 include: Miller/Laguna 950, 900. Standard Clays 108. Cone 5-6: Miller/Laguna Clays 45, 66, 75. Standard Clays: 547, 420, 239. Low Fire Cone 06-04: Miller/ Laguna 10G, 20G, 26, Standard Clays 104, 105G, 239. Atmospheric Clays Atmospheric clays including raku, woodfire, salt fire, and reduction must be durable to withstand the thermal shock or changing temperatures. They should also have good flashing properties if used for woodfiring, salt firing, or reduction. Recommended clays for Cone 10 include: Miller/Laguna Bmix10. Standard Clays: 437, 621, 508, 119, 153, 507. Highwater Clays: Helios, Loafers Glory, Craggy Crunch, Phoenix. For raku use Miller/Laguna 200, 250, or Standard Clay 239.

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https://www.theceramicshop.com/content/425/Clay-Reference-Guide/

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glaze

A glaze is a vitreous substance fused on to the surface of pottery to form a hard, impervious coating. This coating is typically applied after an initial bisque firing occurs, although certain glazes can be singlefired. After a bisqued (or once-fired) piece of pottery is covered with glaze either by dipping, brushing, or spraying, the piece is then fired again, to a temperature appropriate for both the claybody and glaze being used. Generally, these ranges will be either low-fire (pyrometric cone 05-06 is the general range for lowfire) or mid-range (cone 6 being the most popular range). For you, this means that we carry a huge variety of glazes for both low-fire and mid-range pottery. [1] An underglaze is exactly what it sounds like -- a decorative coating that you dip or paint on to greenware or bisqued pottery. After an initial firing, you can then cover the underglaze with a transparent or translucent glaze for added effect, or you can let the underglazes stand on their own. While glazes tend to be vitreous and run together when fired, with underglazes, you can expect a more tightly-controlled, painterly effect. [1] What Exactly is Glaze? Ceramic glaze is basically glass melted onto a ceramic object. Because glaze needs to adhere to an oftenvertical surface while not running off the piece, its component parts are ground into powder and mixed with water and binders so that it can be applied to ceramic pieces. Typical application methods include brushing, dipping, pouring, trailing, and spraying. [1] The Basics of Glaze While applying glaze to a ceramic piece is not absolutely necessary, it can enhance the fired clay piece both on an aesthetic and functional level.Many clay bodies are not vitreous without being glazed. Glazes, by their nature, are vitreous. When glaze is fired onto a piece it seals the clay making it stain resistant and depending on the glaze, food safe. [2] Glaze Categories A glaze’s surface properties can be difficult to categorize due to an infinite number of variables in their ingredients. Here are the basic names you should learn to recognize: Transparent, Opaque, Gloss, Matte, Breaking, Flowing, and then there are the limitless color names added to these descriptive surface names. [2]

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1. https://www.theceramicshop.com/store/department/10/glazes-underglazes/ 2. https://skutt.com/skutt-resources/education/ceramics-101/

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Firing Temperatures

Degrees F C Cone 1305 — 10 10 — 2381

Cone

& Cone Equivalents Showing various clays and glazes

9 — 2336

1280 — 9

8 — 2305

1263 — 8

light yellow to yellow white

Mid-range stoneware & porcelain clays mature (Vashon Clays, Crystal White, Dove, Alpine White, etc. and "A" body clay with underglaze

7 — 2264

1240 — 7

6 — 2232

1222 — 6

5 — 2185

1196 — 5

4 — 2157

1186 — 4

3 — 2134

1168 — 3

Cone 10 Oxidation takes place in the Electric Kiln Reduction takes place in the Gas Kiln

Engobes mature from cone 4 to 10 Mid-range glazes mature (cone 4-6) Max. temp. for most Amaco and other commercial underglazes

firing

yellow-orange to light yellow

From this point up low fire clays will start to melt, damaging shelves and other pots

Low fire clays mature (Terra Cotta, Low Fire White & Earthenware) Ceramic bisque range at BCC**

2 — 2124

1162 — 2

1 — 2109

1154 — 1

01 — 2079

1137 — 01

02 — 2048 03 — 2014

1120 — 02 1101 — 03

04 — 1940

1060 — 04

orange to yellow-orange

Normal or soft bisque for high firing stoneware, porcelains & mid-range clay bodies

05 — 1915

1046 — 05

06 — 1830 07 — 1803

999 — 06 984 — 07

08 — 1751

956 — 08

cherry red to orange

09 — 1693

923 — 09

010 — 1641

894 — 010

011 — 1641

894 — 011

012 — 1623

884 — 012

dull red to cherry red

Burnished low fire clay bisque (for sawdust firing)

013 — 1566

852 — 013

014 — 1540

838 — 014

015 — 1479

804 — 015

016 — 1458

792 — 016

017 — 1377

747 — 017

018 — 1323

717 — 018

019 — 1261

683 — 019

020 — 1175

635 — 020

021 — 1137 022 — 1112

614 — 021

Bisque Firing: done between 1657°F (cone 010) and 1945°F (cone 04)

Wear protective eyewear above 2000°° F Duncan low fire clear and other low fire commercial glazes. (Read the label) Best results for most low fire red and orange glazes at this cone or lower.

Bisque firing is the typical and very important first step in the ceramic finishing process. During a bisque firing both physical and chemical water is driven out of the clay and organic residue burns out. Volatiles like carbon and sulfur combine with oxygen and escape the clay body. Fluxes start melting and reacting with the minerals in the clay body to turn that sticky muddy mess you started with into, well, a rock! This new hardened form will not dissolve when in contact with water nor crumble when handled for glazing. Glaze Firings: done between 1828°F (cone 06) and 2345°F (cone 10)

It is MOST important that you differentiate between cone 06-04 and cone 4-6. Note: the word cone is often replaced with this symbol

Overglaze enamels. Lusters (metallics and irridescents)

Glaze firings are the second and sometimes even the third step in the ceramic finishing process. They involve the heating and melting of glass forming materials applied to the surface of the clay in order to change them into a layer of glass. This type of firing is typically a faster process than that of bisque firing due to the fact we are far less concerned about the amounts of water contained in the items being fired, at least if they have been bisque fired! Unlike in a bisque firing, where it is some what exceptable to have items touching one another, in a glaze firing, items should never be closer than one inch from each other, unless it is your intention to glue then together.

600 — 022

Beginning to show dull red

** 1. Normal or soft stoneware/porcelain bisque can be fired from cone 08 to 04. 2. Low fire white & terra cotta is generally bisque fired at cone 02 to 1. 3. "A" Body clay with underglaze can be bisque fired at cone 4 to 6 & then have a low fire glaze firing at cone 06 to 04. 4. Raku clay is usually bisque fired to cone 04 to 1 5. Clays that are to have crystalline glazes should be bisque fired slightly higher than normal (i.e. high fire porcelain or stoneware - cone 02 to 1)

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Kiln Color

All cones mature with time and temperature All temperature equivalents on this chart are based on a 270°° F (150°° C) per hour rate climb using the large cone. Rates of climb change per firing as do temperature equivalents.

https://www2.bellevuecollege.edu/artshum/materials/art/Husby/FiringTemperatures.pdf

https://skutt.com/skutt-resources/education/ceramics-101/

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materials

210

211

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I l

F m l

m lH m

J li

HrlHÿDI

IHl

0123ÿ5ÿ6789ÿ5ÿ hand forming clay body

ÿ MC #10-G (EM-101)

Talc-free, white firing, grogged/plastic, suitable for throwing and sculpture (This clay has the same properties as the EM-100 Miller #10 but this clay has medium grog added.) This clay is perfict for throwing large and sculptural pieces. *Lower shrinkage* Characteristics: Cone: 06 Wet Color: Gray Firing Color: Oxidation: White - Reduction: N/A Texture: Smooth Penetrometer Target: 7.5 Avg. Shrinkage ±2%: 7.8% Avg. Water Absorption ±1%: 11.5% COE x 10-6: 7.85

87 33 ÿ 3ÿ ÿ 1 3 5 78 ÿ 8!73ÿ 1 ÿ 1 ÿ8 7 3ÿ" ÿ 789ÿ 8 ÿ 3ÿ 823ÿ 1 3 3 ÿ8 ÿ 3ÿ$% &''ÿ% 773 (&'ÿ! ÿ ÿ 789ÿ 8 ÿ23 2ÿ 1 ÿ8 3 )*ÿ ÿ 789ÿ 3 ÿ 1 ÿ 1 ÿ78 3ÿ8 ÿ 7 87ÿ 3 3 )ÿ+,1 3 ÿ -8 3+ . ÿ 12ÿ/0 ÿ0, 1ÿ1 3 ÿ ÿ 789ÿ!1 9ÿ ÿ 9ÿ"1'ÿ7!ÿ2 2 2* ÿ 738 3ÿ 877) ÿ 61 32ÿ'3ÿÿ 43 ÿ6171 2ÿ5 89ÿÿ 0 ÿ6171 2ÿ/6 8 1 2ÿ4 3ÿ ÿ73 1 2ÿ859ÿÿ 36 32ÿ.211 ÿÿ :3 3 123 3 ÿ 8 3 2ÿ;)1ÿÿ 9< )ÿ. -8 3ÿ=>?2ÿ;)@?ÿÿ 9< )ÿ48 3 ÿ9! 1 1 ÿ=&?2ÿ&&)1?ÿÿ 6/$ÿ6ÿ&' 32ÿ;)@1ÿÿ

212

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9!1 ÿ,8 8ÿ6789

klÿmÿnompÿkqrrp 213

3D Printing Clays

PRAI 3D 3d printing clay body

PRAI 3D Item number: 13 310 210 | UPC: 8422830133079

Stoneware for 3D printing The popular PRAI, high fire white body with 40% impalpable grog (up to 80 Mesh) adapted for 3D printing. Its particular white ivory colour after firing is much appreciated and provides an excellent ware for glazes and colouring oxides. Besides, its characteristics offer an excellent behaviour during drying and firing. Available in extruded body with the ideal humidity for 3D printing. Presented in a practical cylindrical format with double packaging. Firing range: Cone 6-10 (2269º-2381ºF) Biscuit: Cone 06 (1855ºF) Water content: 22% Plasticity (IP Atterberg): 16 Carbonate content (CaCO3): 0% Drying shrinkage: ≈ 8.5% Firing shrinkage at Cone 10: 7.0% Porosity (water absorption) at Cone 10: 0.0% Dry bending strength: 3.0 N/mm2 Fired bending strength at Cone 10: 45.3 N/mm2 Thermal coefficient (a25-500ºC): 52.6x10-7ºC-1

Double packaging

PRAI 3DPRAI 3D Item number:13 310 210 | UPC8422830133079 Stoneware for 3D printing The popular PRAI, high fire white body with 40% impalpable grog (up to 80 Mesh) adapted for 3D printing. Its particular white ivory colour after firing is much appreciated and provides an excellent ware for glazes and colouring oxides. Besides, its characteristics offer an excellent behaviour during drying and firing. Available in extruded body with the ideal humidity for 3D printing. Presented in a practical cylindrical format with double packaging. Firing range: Cone 6-10 (2269º-2381ºF) Biscuit: Cone 06 (1855ºF) Water content: 22% Plasticity (IP Atterberg): 16 Carbonate content (CaCO3): 0% Drying shrinkage: ≈ 8.5% Firing shrinkage at Cone 10: 7.0% Porosity (water absorption) at Cone 10: 0.0% Dry bending strength: 3.0 N/mm2 Fired bending strength at Cone 10: 45.3 N/mm2 Thermal coefficient (a25-500ºC): 52.6x10-7ºC-1

11 lb

CERÁMICA COLLET S.A. | Fundada en 1874 Polígono Industrial L'Olana, S/N. E-08292 Esparreguera - Barcelona (SPAIN) T +34 93 777 23 44 | F +34 93 770 94 11 | info@sio-2.com | www.sio-2.com

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https://www.sio-2.com/us/prai-3d/subfamily/100

215

project specific glaze brands and products

SPECTRUM Spectrum’s 1100 glazes comprise a series of cone 4/6 stoneware glazes that are both lead-free and dinnerware safe. Most of them also come with the A/P non-toxic rating from the Art & Creative Materials Institute (ACMI) marked on the product label. Some of the reactive type glazes are rated C/L by the ACMI which means that they are toxic in the liquid (unfired) state due to the presence of heavy metals, such as copper or vanadium, beyond the non-toxic legal limit. C/L rated glazes should not be handled by young children or pregnant women. Spectrum’s Reactive Glazes are all lead free, non-toxic and dinnerware safe. They are formulated to produce reactions during the firing cycle which give very interesting and beautiful effects. The final appearance of the glaze is dependent on firing temperature, glaze thickness and the composition of the clay body being used. The sample shown has 3 coats of glaze brushed on a white clay and is fired to cone 5 in an electric kiln. Spectrum’s Texture Glazes are all lead free, non-toxic and dinnerware safe. They are formulated to produce reactions during the firing cycle which give very interesting and beautiful effects. The final appearance of the glaze is dependent on firing temperature, glaze thickness and the composition of the clay body being used. COYOTE Coyote’s Crawl glazes provide an interesting texture and are great for sculptural work or as an accent on pottery. Try them over another glaze for a variation in texture or use over a bright underglaze for a pop of color. Not recommended for food use. Fires to cone 5 or 6.

216

https://www.theceramicshop.com/store/department/10/glazes-underglazes/

217

1107 BLACK

1141 TEXTURED CASCADE

Spectrum’s 1107 Black cone 4/6 stoneware glaze is a glossy, opaque black glaze. It produces a smooth and even surface. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

Spectrum’s 1141 Textured Cascade is a cone 4/6 stoneware glaze. It produces a greyish surface that is brighter on white clays than on darker ones. Its beauty lies in the surprising colors that come through during firing. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application. S1141 is one of Spectrum’s Reactive Glazes.

1111 HOLLY GREEN

1145 TEXTURED AUTUMN

Spectrum’s 1111 Holly Green cone 4/6 stoneware glaze is a glossy, opaque green glaze. It produces a smooth and even surface, and is brighter on white clays than on darker ones. S1111 is formulated to produce reactions during the firing cycle which give very interesting and beautiful effects. The final appearance of the glaze is dependent on firing temperature, glaze thickness and the composition of the clay body being used.

Spectrum’s 1145 Textured Autumn is a cone 4/6 stoneware glaze. It produces a brown and green surface that is brighter on white clays than on darker ones. This is a great glaze for trees and leaves. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

1114 METALLIC GOLD RAIN

1183 TEXTURED DARK CLOUD

Spectrum’s 1114 Metallic Gold Rain cone 4/6 stoneware glaze. The final appearance of the glaze is dependent on firing temperature, glaze thickness and the composition of the clay body being used.

Spectrum’s 1183 Textured Dark Cloud is a cone 4/6 stoneware glaze. It produces a greenish blue opaque finish. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

S1145 is one of Spectrum’s Reactive Glazes.

S1183 is one of Spectrum’s Reactive Glazes.

218

1126 SATIN BLACK

1188 PEWTER

Spectrum’s 1126 Satin Black cone 4/6 stoneware glaze is an evenly opaque black glaze. It is formulated to produce a smooth and satin finish. This black is a great staple glaze to have - produces reliable results each time! All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

Spectrum’s 1188 Pewter cone 4/6 glaze creates a beautiful metallic finish. This is an opaque glaze that produces a shiny surface.

https://www.theceramicshop.com/store/department/10/glazes-underglazes/

219

1193 FIRE ENGINE RED

1431 PEARL WHITE

Spectrum’s 1193 Fire Engine Red cone 4/6 stoneware glaze is a glossy, red glaze. Kids love these bright colors! It produces a smooth and even surface, and is brighter on white clay than on darker clay bodies. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

Spectrum’s 1431 Pearl White is a cone 4/6 stoneware glaze. All of Spectrum’s Stoneware Glazes are available in wet formats and are suitable for brush application.

1198 OIL SPOT

1436 KIM CHI

Spectrum’s 1198 Oil Spot is a cone 4/6 black finish. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

Spectrum’s 1436 Kim Chi is a cone 4/6 stoneware glaze. All of Spectrum’s Stoneware Glazes are available in wet formats and are suitable for brush application.

S1198 is one of Spectrum’s Reactive Glazes.

S1436 is one of Spectrum’s Texture Glazes.

1118 WHITE

WHITE CRAWL

Spectrum’s 1118 White cone 4/6 stoneware glaze is a glossy opaque white glaze. This glaze will produce a bright white on white stoneware, while producing a more rustic effect on darker clay bodies. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

Coyote’s Crawl glazes provide an interesting texture and are great for sculptural work or as an accent on pottery. Try them over another glaze for a variation in texture or use over a bright underglaze for a pop of color. Not recommended for food use. Fires to cone 5 or 6.

S1431 is one of Spectrum’s Texture Glazes.

1166 BRIGHT ORANGE Spectrum’s 1166 Bright Orange cone 4/6 stoneware glaze is a glossy, orange glaze. This is a favorite among school age children! It produces a smooth and even surface, and is brighter on white clay than on darker clay bodies. All of Spectrum’s 1100 Stoneware Glazes are available in wet formats and are suitable for brush application.

220

https://www.theceramicshop.com/store/department/10/glazes-underglazes/

221

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225

— Movement

— Specification

—

Robot version

R O B OT I C S

IRB 4600 Industrial Robot IRB 4600 is a highly productive general purpose robot optimized for short cycle times where compact robots can help create high density cells. The IRB 4600 enables more compact manufacturing cells with increased production output and higher quality - and that means improved productivity.

Reach (m)

Payload (kg)

Armload (kg)

Axis movement

Working range

Axis max. speed

Axis 1 rotation

+180° to -180°

175°/s

IRB 4600-60/2.05

2.05

Axis 2 arm

+150° to -90°

175°/s

IRB 4600-45/2.05

2.05

Axis 3 arm

+75° to -180°

175°/s

IRB 4600-40/2.55

2.55

Axis 4 wrist

+400° to -400°

250° (360° for IRB 4600-20/2.50)

IRB 4600-20/2.50

2.51

Number of axes

6+3 external (up to 36 with MultiMove)

Axis 5 bend

+120° to -125°*

250° (360° for IRB 4600-20/2.50)

Protection

Standard IP67, as option Foundry Plus 2

Axis 6 turn

+400° to -400°

360° (500° for IRB 4600-20/2.50)

Mounting

Floor, shelf, inverted or tilted

*IRB 4600-20/2.50, +120° to -120°.

Controller

IRC5 Single cabinet

Working range, IRB 4600-60/2.05, IRB 4600-45/2.05

Path repeatability*

IRB 4600-60/2.05

0.06 mm

0.46 mm

IRB 4600-45/2.05

0.05 mm

0.13 mm

IRB 4600-40/2.55

0.06 mm

0.28 mm

IRB 4600-20/2.50

0.05 mm

0.17 mm

1260

Position repeatability

2371

— Performance (according to ISO 9283)

*Measured at speed 250 mm/s.

— Technical information

1028

593

1701

2051

Electrical Connections Supply voltage

Working range, IRB 4600-40/2.55 IRB 4600-60/2.05

200-600 V, 50-60 Hz

IRB 4600-45/2.05

Physical Robot base

Best protection available ABB has the most comprehensive protection program on the market and it will be even further enhanced with the IRB 4600. Foundry Plus includes

226

IRB 4600-40/2.55

1922 mm

IRB 4600-20/2.50

1922 mm

2872

1727 mm

IRB 4600-60/2.05

425 kg

IRB 4600-45/2.05

425 kg

IRB 4600-40/2.55

435 kg

IRB 4600-20/2.50

412 kg

1735

Robot weight

1393

680

2202

2552 IRB 4600-40/2.55

Environment

To simulate your production cell to find the optimal position for the robot and program it offline, RobotStudio is available on subscription together with PowerPacs for several applications.

Working range, IRB 4600-20/2.50

Ambient temperature for mechanical unit

Learn more about how to use the IRB 4600 in your applications and environments - watch simulations on several applications at www.abb.com/robotics. Main applications • Arc Welding • Assembly • Material Handling • Machine Tending • Material Removal • Cleaning/Spraying • Dispensing • Packing • Laser Cutting • Laser Welding

1727 mm

IRB 4600-45/2.05

During operation

+5° C (41° F) to + 45°C (113°F)

During transportation and storage

-25° C (-13° F) to +55° C (131° F)

During short periods (max. 24 h)

up to +70° C (158° F)

Relative humidity

Max. 95%

Safety

Double circuits with supervisions, emergency stops and safety functions. 3-position enable device

Emission

EMC/EMI shielded

Data and dimensions may be changed without notice.

1361

665

2163

— abb.com/robotics

—

We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

2513 IRB 4600-20/2.50

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB. Copyright© 2020 ABB All rights reserved

ROB0109 EN Rev.L December 2020

Compactness The small footprint, the slim swing base radius around axis 1, the fine elbow behind axis 3, the small lower and upper arms, and the compact wrist all contribute to the most compact robot in its class. With the IRB 4600 you can create your production cell with reduced floorspace by placing the robot closer to the served machines, which also increases your output and your productivity.

Optimize and go sharp To get the IRB 4600 ready for the targeted applications you have access to high performing workpiece positioners, track motions, and the motor and gear unit range.

IRB 4600-60/2.05

2833

Ultra-wide working range You can position the IRB 4600 in the most favourable way with regard to reach, cycle time and auxiliary equipment. Flexible mounting with floor, tilted, semishelf or inverted mounting is very useful when you are simulating the best position for your application.

512 x 676 mm

Height

IP 67, resistant paint, rustprotected mounting flange and protection for molten metal spits on non-moving cables on the rear of the robot and extra protection plates over the floor cable connections on the foot.

1696

Shortest cycle times Thanks to the new compact and optimized design resulting in a low weight, the IRB 4600 can cut the cycle times of the industry benchmark by up to 25%. The maximum acceleration achievable is highest in its class, together with high maximum speeds. With the high acceleration it is possible to use to avoid obstacles or to follow the path. The benefit is increased production capacity and higher productivity.

227

— Specification

— Movement

—

Robot version

Reach (m)

Handling capacity (kg)

Armload (kg)

IRB 120

IRB 120-3/0.6

0.58

0.30

Number of axes

Axis movement

Working range

Velocity IRB 120

Axis 1 rotation

+165° to -165°

250°/s

Axis 2 arm

+110° to -110°

250°/s

Axis 3 arm

+70° to -110°

250°/s

Protection

IP30

Axis 4 wrist

+160° to -160°

320°/s

Mounting

Any angle

Axis 5 bend

+120° to -120°

320°/s

Controller

IRC5 Compact/IRC5 Single Cabinet

Axis 6 turn

420°/s

Integrated signal supply

10 signals on wrist

Integrated air supply

4 air on wrist (5 bar)

Default: +400° to -400° Max. rev: +242 to -242

R O B OT I C S

ABB’s 6 axis robot – for flexible and compact production The IRB 120 robot is the latest addition to ABB’s new fourthgeneration of robotic technology. It is ideal for material handling and assembly applications and provides an agile, compact and lightweight solution with superior control and path accuracy.

* 4 with vertical wrist

— Performance (according to ISO 9283) Working range

IRB 120 1 kg picking cycle 0.58 s

25 x 300 x 25 with 180° axis 6 reorientation

0.92 s

Acceleration time 0-1 m/s

0.07 s

Position repeatability

0.01 mm

R tu

982

25 x 300 x 25 mm

— Technical information

The Food Grade Lubrication (NSF H1) option includes Clean Room ISO Class 5, which ensures uncompromising safety and hygiene for food and beverage applications. Optimized working range IRB 120 has a horizontal reach of 580 mm, the best in class stroke, the ability to reach 112 mm below its base and a very compact turning radius.

228

411 580

Robot base

180 x 180 mm

Robot height

700 mm

Robot weight

25 kg

580

165°

Environment

Ambient temperature for robot manipulator:

IRC5 Compact controller – optimized for small robots ABB’s new IRC5 Compact controller presents the capabilities of the IRC5 controller in a compact format. It brings accuracy and motion control to applications which have been exclusive to large installations and enables easy commissioning through one phase power input, external connectors for all signals and a builtin expandable 16 in, 16 out, I/O system.

Reduced footprint The combination of the new lightweight architecture of the IRB 120 with the new IRC5 Compact controller introduces a significantly reduced footprint.

0.24 kW

Physical

Fast, accurate and agile Designed with a light, aluminum structure, the motors ensure the robot is enabled with a fast acceleration, and can deliver accuracy and agility in any application.

RobotStudio for offline programming enables manufacturers to simulate a production cell to find the optimal position for the robot, and provide offline programming to prevent costly downtime and delays to production.

Power consumption

580

— abb.com/robotics

During operation

+5°C (41°F) to +45°C (113°F)

During transportation and storage

-25°C (-13°F) to +55°C (131°F)

During short periods (max. 24 h)

up to +70°C (158°F)

Relative humidity

Max. 95%

Noise level

Max. 70 dB (A)

Safety

Safety and emergency stops 2-channel safety circuits supervision, 3-position enabling device

Emission

EMC/EMI-shielded

Options

Clean Room ISO class 5 (certified by IPA)**

411

R121 Minimum turning radius axis 1

165°

580

** ISO class 4 can be reached under certain conditions. Data and dimensions may be changed without notice.

—

ROBO149EN_D Rev. J November 2019

Multipurpose IRB 120 is ideal for a wide range of industries including the electronic, food and beverage, machinery, solar, pharmaceutical, medical and research sectors.

3.0 kVA

982

IRB 120 is also the most portable and easy to integrate on the market with its 25 kg weight. The smooth surfaces are easy to clean and the cables for air and customer signals are internally routed, all the way from the foot to the wrist, ensuring that integration is effortless.

200-600 V, 50/60 Hz

Rated power transformer rating

112

Compact and lightweight IRB 120’s compact design enables it to be mounted virtually anywhere at any angle without any restriction - for example inside a cell, on top of a machine or close to other robots.

Supply voltage

112

Electrical Connections

229

—

R O B OT I C S

IRC5 Industrial Robot Controller Based on more than four decades of robotics experience, the IRC5 is the robotic industry’s benchmark in robot controller technology. In addition to ABB’s unique motion control it brings flexibility, safety, modularity, application interfaces, multi-robot control and PC tool support. The IRC5 comes in different variants to provide a cost-effective and optimized solutions for every need.

Fast and accurate The IRC5 gives our robots the ability to perform their tasks in a highly efficient manner. Based on advanced dynamic modelling, the IRC5 automatically optimizes the performance of the robot by reducing cycle times (QuickMove®) and providing precise path accuracy (TrueMove®). Thanks to ABB’s IRC5 technology, a robot’s motion is predictable and its performance high, with no tuning required by the programmer. What you program is what you get. Safe Operator safety is a leading benefit of the IRC5. It fulfills all relevant regulations and is certified by third party inspectors worldwide. SafeMove2 represent a new generation of safety, enabling more flexible robotic cell safety concepts, e.g. enabling floor space reduction and collaboration between robot and humans. Compatible No matter where in the world your robot is located, and regardless of what regulatory standards apply, the IRC5 is up to the task. ABB’s controller is compatible with various types of main voltages and can handle a broad spectrum of environmental conditions. IRC5 communicates with other machines in a manufacturing environment; in a safe and predictable way.

230

It supports the majority of all state-of-the-art industrial networks for I/O. Sensor interfaces, remote access and a rich set of programmable interfaces are examples of the IRC5’s many powerful networking features. Programmable All ABB robot systems are programmed with RAPIDTM, ABB’s flexible, high-level programming language. On the surface RAPID’s basic features and functionality are easy to use, but dig deeper and you will find that this programming language allows you to create highly sophisticated solutions. It is a truly universal language on and off the shop floor which supports structured programs, and advanced features. It also incorporates powerful support for the most common robot process applications such as welding and assembly. Reliable The IRC5 is practically maintenance free, and its outstanding quality ensures unmatched up-time. Built-in diagnostic functions help ensure fast recovery and production restarts when operations are interrupted on the factory floor. The IRC5 also comes equipped with remote monitoring technology, ABB Ability Connected Services. Advanced diagnostics allow quick investigation of failures as well as real-time monitoring of the robot condition throughout its lifecycle; all made to increase your productivity.

231

IRC5 Single Cabinet Controller • Designed for high IP protection and full expandability. • Provides a protected environment for axillary equipment in the robot system. • Capable of control of up to four robots in a MultiMove® setup. Just add a compact drive module to each additional robot. • MultiMove® opens up previously unthinkable operations, thanks to the perfect coordination of complex motion patterns.

Electrical Connections Single phase 220/230 V, 50-60 Hz

Physical

Electrical Connections 3 phase, 200-600 V, 50-60 Hz

FlexPendant The FlexPendant is characterized by its clean, color touch screen-based design and 3D joystick for intuitive interaction. Powerful support for tailormade applications, e.g. operator screens. — Technical information, FlexPendant

Dimensions

320 x 449 x 442 mm

Environment

Weight

28.5 kg

Functions

Graphical color touch screen Joystick Hot plug- Add/remove during operation Membrane keyboard with 12 buttons USB Memory support

Safety functions

Emergency stop 3-position enabling switch (dual circuit)

Degree of protection

IP54

Environment

Physical Dimensions Single cabinet

RobotStudio Online RobotStudio Online is a suite of tablet applications for shop floor operations. Utilizing the familiar and user-friendly nature of tablets, these applications make it easy to perform operations such as calibration, editing programs or jogging. Combined with an ABB Jokab Safety three position enabling device safety is not compromised.

— Technical information

Supply voltage

— Technical information Supply voltage

IRC5C Compact Controller • Offers the capabilities of the powerful IRC5 controller in a compact format. • Delivers space saving benefits and easy commissioning through one phase power input • External connectors for all signals and a built in expandable 16 in, 16 out I/O system.

970 x 725 x 710 mm

MultiMove® drive modules 720 x 725 x 710 mm

Ambient temperature

0-45°C

Relative humidity

Max. 95% non condensing

Degree of protection

IP20

Weight 150 kg

Environment Ambient temperature

0-45°C, optional: 0-52°C

Relative humidity

Max. 95% non condensing

Safety

SafeMove: Supervision of stand-still, speed, position and orientation (robot and additional axes): 8 safe inputs for function activation, 8 safe monitoring outputs

Extended safety

Electronic Position Switches: 5 safe outputs monitoring axis 1-7

Degree of protection

IP54 (cooling ducts IP33)

— Technical information, JSHD4-3 Three position device Environment

— abb.com/robotics

232

—

Functions

LED status diods

Safety functions

Emergency stop 3-position enabling switch (dual circuit)

Degree of protection

IP65

ROB0295EN Rev. D June 2019

Single cabinet

MultiMove® drive modules 130 kg

233

Robotics

The IRBT X004 from ABB is the only track motion platform on the market to guarantee high speed, precision accuracy, and great flexibility.

Robot

Travel length

No of robots

IRBT 4004

IRB 4400/ 4450S/4600

1.9... 19.9 m/1 m step

One or two/track

Floor

IRBT 6004/ 7004

IRB 6620/6650S/6700

1.7... 19.7 m/1 m step

One or two/track

Floor

IRBT 7004

IRB 7600

1.7... 19.7 m/1 m step

One or two/track

Floor

Cable arrangement Plastic with cover - standard Pos to Pos time (s) *)

IRBT 4004

< 1.2

< 1.7

< 2.2

< 2.7

< 3.2

IRBT 6004

< 1.5

< 2.1

IRBT 7004

< 1.7

< 2.6

< 2.8 < 3.4

< 3.4 < 4.2

*) With max load

< 4.0 < 5.0

Mounting pos

IRBT 4004/6004/7004 Track Motions for robots

Acceleration/Retardation (m/s2) X004 IRB 4004

2.5*

IRB 6004

2.0*

IRB 7004

1.8*

* Dep. on actual load

Speed (m/s)

Outstanding speed and accuracy

Options

IRB 4004

2.0

As first on the market, ABB’s track motions and its respective robot is a seven-axis dynamic model. ABB’s unique QuickMove and TrueMove can be fully exploited, which means optimal movement for the robot and the track with actual load. Furthermore, path accuracy and speed are optimized.

− − − −

IRB 6004

1.6

IRB 7004

1.2

The speed position-to-position, which is the real benchmark of the capability of the track, has improved by more than 40% compared to earlier models.

Benefits − Path accuracy best in class − Simple, robust and compact design − Less parts, many common modules for complete range − Easy to adjust at installation and start up − The same mechanical footprint of the track for all robot models − Improved performance − Shorter cycle time − Improved path accuracy − Robot position chosen at installation − Wide range of options for different applications

234

Mirrored version Double carriages Pedestals Customer Signal and power cable (spot welding, material handling, etc) − Lubrication (standard = manual lubrication) − Prepared for local adaptation (no pump included) − Central lubrication system incl pump − Foundry − Travel length from 1.9 to max 7.9 for IRBT 4004 − From 1.7 to max 7.7 for IRBT 6004 and 7004 − Cable arrangement

For more information please contact: ABB AB Robotics Hydrovägen 10 SE-721 36 Västerås, Sweden Phone: +46 21 325000 www.abb.com/robotics Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents - in whole or in parts – is forbidden without prior written consent of ABB. Copyright© 2016 ABB All rights reserved

235

Manual, Robotic Tool Changer, QC‑76 Document #9620‑20‑B‑76 Series Base Tool Changer‑19

1.1

1.2

Master Plate Assembly

Tool Plate Assembly The Tool plate assembly includes the following features:

The Master plate assembly includes the following features: •

An anodized aluminum body

•

An anodized aluminum body

•

A hardened stainless steel locking mechanism (a cam, male coupling, and chrome steel ball bearings)

•

A hardened stainless steel bearing race

•

Hardened stainless steel alignment pins that mate with bushings on the Tool plate

•

Alignment bushings that mate with pins on the Master plate

•

(2) flats for mounting optional modules

•

(2) 1/8 NPT, G 1/8 (BSPP) or Rc 1/8 (BSPT) connections to supply pneumatic pressure for coupling and uncoupling the Tool Changer

(5) 3/8 NPT, G 3/8 (BSPP) or Rc 3/8 (BSPT) connections to pass air/or vacuum through the Tool Changer

•

(2) flats for mounting optional modules

•

(5) 3/8 NPT, G 3/8 (BSPP) or Rc 3/8 (BSPT) connections to pass air and/or vacuum through the Tool Changer

•

A machined mounting pattern for mounting to customer tooling or an interface plate

•

Proximity sensor assemblies are used to verify the lock/unlock position of the piston and cam

•

A machined mounting pattern for mounting to a robot arm or an interface plate

An optional RTL sensor target and sensor block used to verify Tool plate presence when coupled, can be ordered separately. Figure 1.2—Tool Plate Assembly

An optional RTL sensor and sensor block used to verify Tool plate presence when coupled, can be ordered separately.

(5) 3/8 NPT, Rc 3/8 (BSPT), or G 3/8 (BSPP) Customer Connection

An extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance performance and maximize the life of the Master plate.

Flat B for Mounting Optional Module

Figure 1.1—Master Plate Assembly (Shown with Optional Sensors)

(5) 3/8 NPT, Rc 3/8 (BSPT) or G 3/8 (BSPP) Customer Connection

Flat B for mounting optional modules

Proximity Sensor Target (RTL Sensor) Bearing Race

Proximity Sensor Assembly (RTL Sensor)

(5) Pass-through Air Port

Proximity Sensor Assembly (Unlock and Lock Sensors)

Flat A for Mounting Optional Module

Flat A for mounting optional modules

(2) Alignment Pin Bushing

Cam

(6) Ball Bearing

(5) Pass-Through Air Port

Male Coupling

1.3

(2) Alignment Pin

Optional Modules There are (2) flats for mounting optional modules with the J16 mounting pattern, which pass utilities to customer tooling. The J16 mounting is a M4X0.7 thread on an 18 mm high and 50 mm wide rectangular pattern. For assistance in choosing the modules for your particular application, visit our website (QC‑76 Series) to see what is available or contact an ATI sales representative directly.

236

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com

B-4

B-5

237

238

239

240

241

KMT-714 KMT-714

Volts

KMT-714 1

Opening Amps Watts Cu.Ft. A B C D E F 120/208-240 Cone Temp Depth Width 10 8 2300 13.5 14.00 1.4 18.5 19.5 2.5 8 17 18 20 3600

714 ROLLING STAND NON Optional ADJ LINKBOARD SERVICE 1 YEAR Optional LINKBOARD SERVICE 5 YEAR Optional

242

Maximum

Chamber

O.D.Dimension

Power

Copper NEMA Wire Recp. BTU's Size Conf.

MODEL Phase

14-30 9500

Thermocouple: K Clock: 60 Mhz Voltage: 24 DC Relays Output: 12 Volts DC Fuse: 0.5 AMP

243

KMT-1227PK KMT-1227PK

MODEL

Phase

KMT-1227PK 1

Maximum

240

Opening Amps Watts Cone Temp Depth Width Cu.Ft. A B C D E F 4 10 2350 27 28.00 9.9 33 34 3 8 24 18 60 14300

1227 ROLLING KILN STAND ENVIROLINK ENVIROVENT 2 LINKBOARD SERVICE 1 YEAR LINKBOARD SERVICE 5 YEAR

244

Optional Optional Optional Optional Optional

Chamber

Thermocouple: K Clock: 60 Mhz Voltage: 24 DC Relays Output: 12 Volts DC Fuse: 0.5 AMP

O.D.Dimension

Power

Copper NEMA Wire Recp. BTU's Size Conf.

Volts

Direct 24540 Wire

MODEL

Phase

KMT-1227PK 3

Maximum

208

Opening Amps Watts Cone Temp Depth Width Cu.Ft. A B C D E F 6 10 2350 27 28.00 9.9 33 34 3 8 24 18 46.7 14300

1227 ROLLING KILN STAND ENVIROLINK ENVIROVENT 2 LINKBOARD SERVICE 1 YEAR LINKBOARD SERVICE 5 YEAR

Optional Optional Optional Optional Optional

Chamber

O.D.Dimension

Power

Copper NEMA Wire Recp. BTU's Size Conf.

Volts

Direct 24540 Wire

Thermocouple: K Clock: 60 Mhz Voltage: 24 DC Relays Output: 12 Volts DC Fuse: 0.5 AMP

245