Fluidity_Studio_roboto by Tianzhu Zhang

S T U D I O ROBOTO //INDUSTIAL DEISN NAME: TIANZHU ZHANG STUDENT NUMBER: S3502752

Contents

1 INTRODUCTION 1.1 ISF initial attempt (task1) 1.2 3D Printing initial attempt (task2) 1.3 Foam cutting initial attempt (task3) 1.4 Looking forward to next stage (task1)

1 2 10 18 29

2 IDEATION 2.1 Reference (week6) 2.2 ISF Ideation (week7) 2.3 Foam cutting stool Ideation (week 8) 2.4 Foam cutting stool ideation 2 (week9) 2.5 Foam cutting bench ideation 3 (week10) 2.6 Foam cutting bench final idea (week11)

35 36 38 42 43 48 49

3 REFINEMENT OF Final CONCEPT 3.1 Fluidity concrete part refinement (week10/11) 3.2 Fluidity seating part refinement (week10/11) 3.3 Robot programming (week12/13) 3.4 Concrete cast testing(week10/11) 3.5 Optimazition of material Consumption(week12/13) 3.6 Simulation(week12/13)

50 52 53 54 57 59 60

5 PROCESS 5.1 Fusion 360 modelling 5.2 Making process

61 62 64

6 FlUIDITY FINAL CONCEPT 6.1 Hero shot & description 6.3 Robotic Fabrication Reflection 6.4 Fusion 360 Reflection

68 69 73 74

Introduction

ISF initial attempt (task1) 3D Printing initial attempt (task2) Foam cutting initial attempt (task3)

1.1 ISF initial attempt (task1)

[ Research and explore ]

Incremental Forming - Workshop @ DADA 2015 2 ISF in Architecture - Ammar Kalo and Michael Jake Newsum 3 Expriment of ourself - RMIT Architectural Robotics Lab

[ Form finding by Fusion 360 ]

3 symmetry cylinders being the based

Bridge the center gap

Stretch the edges of bridges Stretch outer edges and pull up the middle lines of bridges

Revolve “M” shape

Revolve ‘N’ shape profile

Uncrease edges

Uncrease sharp edges

Set up symmetry and pull outside edge out and twist 30 angle

Stretch boarder of the shape

Split the stretched bawl shape

Pull up the top mid-edge

Pull up top edges based on sides symmetry

Fusion 360 is very versatile software expacially the sculpture mode, complex form can be made by it as same as mulnipulating clay on hand. I was thinking what is the unique point of it and how to do form finding by it, not sculpture a shape which has been in the head already. By watching tutorial and talking with mates, the SYMMETRY commond under this mode draws my attention. It feels like rational and all the move are connected by this geometry bond. Whenever one part is pulled up the others will move as well, there are relationships in the action.

[ Programming attempt 1 ]

The first attempt to write an algorithm for incremental sheet forming, inspired by former rearch. I try to use algorithm to add complex pattern on whatevery the target geometry is. The pattern can be accessed by incremental sheet forming after finishing the main form.

[ Programming attempt 2 ]

In this time, the target is to generate paths for robot to changing the tool path without cutting through actual form. Based on the original codes, the triangle path, which move tool away being ready for next path,are modified to rectangle, because the shapes i designed have high raised shape in the center triangle can make sure one side but not other side of the center area. As the trade off, forming time increases dramatically due to the longer distance.

[ Experiment ]

[ Problem Finding ]

After the hands on experiment, I found this form is not able to be done only by one robot, because the outer edge will push the plain backwards where the center raised area is. In the opposite, the outer edge was greatly formed due to the frame support. These discovery will be adapted to the look forward section.

[ Product concept ]

Spetal bread plate

EYE candle holder

Melting Capsicum plate

SMO tableware includes 3 pieces, which function as candle holder, dining plate, and bread plate separately. They are suitable for modernism and minimalist living style because the clean shape without decorations and original material color which can match varieties of context. Their sleek shapes are derived from Georg Jensen as precedent. Robotic incremental sheet forming, functions of them and Fusion 360 model processes are three main factors to cause and develop the form of designs.

1.2 3D Printing initial attempt (task2)

[ Form finding by Fusion 360 ]

Some forms of testing non periodical surface of lamp purpose. After the experiment in fusion, all the forms start to gather up and the final idea became clear _ the Spedrol.

Based sketch

Extrude up the sketch in sculpt mode

Scale up bottom control lines, and adjust the top control lines

The research I have done shows a lot of designs based on this process have a common attribute that the form of them are periodic. I attempted to find a way that can make robot 3d print the form which is not a circle like shape. By adding a small chunk of code, it becomes possible. Fusion 360 is the software i used to experiment and explore forms and ideas.

[ Programming attempt 1 ]

Direction changing of lines, tool will go forth and back transiting to next layers.

The start point of second layer is right upon the end point of the first layer.

In the first part of the algorithm, I dispatched the contours to 2 groups using the ture-false pattern, then flip the direction of second group curves to align the start points to the last end point. Weaving command cross the dispatched data one by one into one list .By doing this, robot can reverse the direction and extrude plastic in non-periodical way. The yellow group visually shows the direction of result curves. The speed of tool movement is set to the different speed to cope with the temperature issue effecting solidification of the material.

[ Experiment with KUKA ]

[ Problem Finding ]

The original speed setting was 35mm/s,it was too fast to solidify the extruded plastic especially where the paths become shorter as coming to top and the point tool changes layer and direction. These imperfection could be resolved by programming the uniform speed to non- uniform speed, which has two way, one is speed is decided by path distance and how close to the two end point where layer and direction change.

[ Problem Solving ]

Speed change according to path length

Speed change according to layer transition

Using python plug-in in grasshopper to set tool moving speed according to the path length. Tool should slow down as doing the shorter path because extruded plastic need time to cool down.

[ Problem Solving ]

Based on the last step speed setting, a modification which the start and the end of path are set to lower speed is added. It can give plastic time to cool at layer transition where the tool will immediately return.

[ Product concept ]

Spedrol serves as a ceiling lamp, as the light on, it unrolls the light in an unique way to reflect its insight, Layer structure also helps the form to spread light and create different appearances at any perspective. The birth of the from are given by taking the advantages and looking after limitations of all the processes from Cad model (fusion 360) to robotic 3d printing technology. In addition, the form can be used as another lamp type like floor lamp or table lamp.

1.3 Foam cutting initial attempt (task3)

[ Form finding ]

Experiment has been done with 3 parts, Sketching, Caid modelling and Hands on cutting. In these playful experiment, the character of the foam and possibility of hot wire cutting became clear. The hard thing here was to find suitable functions and match it with form, questions were asked by myself, why this form is for Robotic form cutting, why the function goes with the form and why people need this product.

[ Form finding ]

In caid model, I found that spacial curve can be realized by this process, when two planer cuts come to intersect with each other, the intersections are spactial curves. It is interesting to cut foam in a planar way, where beautiful patterns can be done.

[ Form finding ]

Hands on cutting is greatly different with computer modelling, I really enjoy cut the wave like shape. The reason why cut like wave is that the two curves which are used for lofting ruled surface are staggered but the numbers of raised parts are same to loft properly.

[ Concept details ]

The details and structure were sort out at this stage. Reasonable post processes were matched with different forms and functions.

[ Concept details ]

[ Concept making process ]

Slip molding porcelain

[ Concept Render ]

Fomake Fomake are all based on the robotic foam cutting Technology, and taking it further to real product concept. Post processes are involved into the production diagram of them, where the diversity is. Foam cutting process sparks these different forms, user perspective thinking fits these pure form to their matching functions. All of them are minimalist, being perfectly suitable to the modern interior context.

[ Concept Render ]

Robotic manufacturing method research

Form finding Function follows using Fusion 360 form

Programming robot with

Robot operation and experiment

Looking forward Multi_layer incremental sheet forming

[Description ]

The idea about multi-layers forming was sparked as I was experimenting with first Task. I found, for the form which has raised area in the center, itâ&#x20AC;&#x2122;s really hard to make by using one robot in front of the frame and pushing one direction. The middle area will move with the plane which has already been pushed back as the robot doing the outer edge, so literally the center will be flat, unless there is something against behind. This observation provides the solution to make complex form, not just a single direction bowl, which is form could be constructed by layers from center to outer edge, using multiple incremental sheet forming.

[Description ]

Form variation

[Description ]

Sequence of layers

3 1

3 2 3

2 2 1 1

The form was constructed in a way that the sequence is from center to outer. Depending on the sequence, form is divided and distributed to different layers. For each layer, top edge must be flat, so if the layer is in the middle, it should have flat top and bottom.

[Description ]

Layer direction

Every layer will be separately incremental formed one by one depending on their order. There is an interesting chance born from this, which is the direction of layer (forming direction) could be different every time.

[Description ]

Cross layer

Higher layer have privilege to generate stretchability of the material.

Cross Layer

Cross layer

structure. It can cross many layers limited by the

2 IDEATION

Reference (week6) ISF Ideation (week7) Foam cutting stool Ideation (week 8) Foam cutting stool ideation 2 (week9) Foam cutting bench ideation (week10) Foam cutting bench final idea (week11)

[ Concept Render ]

1 Spotty 2015 Ammar Kalo 2

N-Bowls Ammar Kalo

[ Concept Render ]

1 Bug-Out-Bug (B.O.B.) 2 Incremental Sheet Metal Forming Ammar Kalo

[ ISF ideation (week7) ]

The first ideation of ISF process tried to explor its possibility in product application. there are lounge chair, lamp, and room divider. all the form are generate to has the complexity which matches the advatages of robotic fabrication.

[ ISF ideation 2 (week7) ]

The advantage of robotic fabrication are shown in this concept, I tried to transfer the famous painting in to the roon divider by algorithem, adding personal faverate into product, then it can be customized to fit people's like. The scale of this deisgn is not practical accroding to the discussion, so next step i tried to separate them into small parts.

[ ISF ideation 2 (week7) ]

The first three images show the variation of the concept which is generated by painting, but these are improved to smaller scale which is possible to produce. The bottom three images are designed to simulate water flow from top to bottom by agent based simulation. The path of simulation can be turned into path for robot to generate the form. The method has been used in archetecture to simulate roof drain system. By evaluating functions and form, these ideas were found lack of considerations and need to be more practical for both fabrication and application.

[ ISF ideation 2 (week7) ]

Multiple panels are adapted in this ideation stage to detach huge scale into small modulars, then used by ISF process. They show the same iusses as previous concepts, lacking function is the disadvantage of them.

[ Foam cutting stool Ideation (week 8) ]

These forms are involved two dimensional changed surface which is not ruled normally, but by dividing them into many sigments it becomes possible for foam cutting process.

[ Foam cutting stool ideation 2 (week9) ]

[ Foam cutting bench ideation (week10) ]

[ Foam cutting bench final concept (week11) ]

This is the concept we choosed for the final object, two making processes are used in it, CNC cut columns and concrete ends which are casted using robotic cut foam mould. Comparing with other bench ideas, this has more contemporary characteristic and show the strength of robotic fabrication. The two ends are inspired by the shape form first 5 weeks foam cutting experiment.

Refinement of Final Concept

Fluidity concrete part refinement (week10/11) Fluidity seating part refinement (week10/11) Robot programming (week12/13) Concrete cast testing(week10/11) Optimazition of material Consumption(week12/13) Simulation(week12/13)

[ Problems analyzing ]

2 1

Three problems were identified in this stage. The first is the straight profile increasing the perception of heaviness of the concrete, which is unwanted. The second one is the top is not flat affecting the comfortability of sitting experience and number of people sitting on it. The third one can be improved to extend and blend the curved surface in to timber columns.

[ Fluidity concrete part refinement ]

These changes are made to resolve the problems found from last form. The second image shows the change of blending the curved surface into the timber part. The last one adjusts the top curvature to make it more agronomical.

[ Fluidity seating part refinement ]

These middle part adjustment are correspond the concrete parts changes. The last step changed the curvature of the surface to fit human body preventing uncomfortable sitting experience.

[ Mold making process ]

The casting mold includes 8 robot cut foam, 1 laser cut lid and 3 metal tubes. these tubes are slots of connecting concrete to the timber parts.

[ Robot programming ]

Part 1 cutting

STEP 1

STEP 2

Cutting path Grab point

Cutting path

Positioning corner

The cutting process has 4 groups of action and totally 8 cut. In-between every cut there is a grabbing point change. There are some extra cuts to clean the surface which is going to attach another mould part. These small cut can increase the accuracy because every block of foam have bit size variation. As changing the grab points, a position corner, which has to be a intact corner, is required to reposition the foam block to the pick-up routine of robot.

[ Robot programming]

4 PARTS 8 STEPS

[ Concrete cast testing ]

The easiest concept was chosen to test the concrete casting. There are two ratio used for casting, more sand and more cement.

[ Concrete cast testing]

The ration of 1Cement to 3 sand is not desired ratio, which make the concrete too fragile. Based on this experiment we decide use the formula (26.6L of concrete 40L of sand 10L water all together) for the final concept making.

[Optimazition of material Consumption]

C-locking optimize the materal usage from 3 sheets to 2 sheets, 25% reduction of usage is achieved by it.

[ Product Simulation ]

The simulation is conducted in fusion 360, insuring the design to be achievable.

PROCESS

Fusion 360 modelling Making process

[ Fusion 360 modelling process ]

Normal matching LOFT

Cross matching LOFT

Wing-like cut

[ Fusion 360 modelling process ]

In sculpture mould, the two profiles are lofted together and then adjusted into a arc shape to increase the fluidity of the form. the material cost also has been reduced due to the shape. The final columns are done by extrude cut of patterned rectangles.

[ Making Process ]

Robot hot-wire cut the foam mould into desired shape. After all the parts are ready, polyurethane vanisher are brushed on the foam surface several coats to smooth them and also for the ease of mould releasing.

[ Making Process ]

Foam moulds were builded ready to cast concrete, tubes also cut to length and positioned vertically, which can be seen in Spirit level. 109 spacers have been cut in metal bend saw to keep every profile away from each other.

[ Making Process ]

Timber profiles are machined out by CNC router and then taken to be sanded and vanished manually to protect it from damage. After finishing, three all threaded metal bars string profiles and spacers together tightly.

[ Making Process ]

Concrete has been casted in the mould made of foams. Originally, we intended to put foam inside to reduce the weight, but it failed because of floating force. Acrylseal are brushed on to the surface of concrete to incease the durability and prevent dust users clothes.

FLUIDITY

TEAM MEMBER: Christian Terlato，Samuel Mulkearns，Peter Higgins，Hao Wu，Anh Dong，Tianzhu Zhang

FINAL CONCEPT

Heroshot & Description Robotic Fabrication Reflection Fusion 360 Reflection

[Heroshot & Description]

FLUIDITY

FLUIDITY is a bench designed for industrial modern interiors. The cold concrete and beige plywood create a sophisticated bend of natural and manufactured materials making it suitable for this context. The form is simple with slight fluid curve, yet engaging as this philosophy repeats throughout the design. FLUIDITY is suited in isolation as it fills a space with its visual impact.

[Heroshot & Description]

Robotic fabrication was used to fulfill our vision as precision is needed to cut mathematic equations which are beyond human capabilities. The concrete form was cast from robotic cut foam which was designed using ruled surfaces, a limitation of this method. However the boundary was pushed as the form does not appear geometric .It appears fluid in style. The seat itself was made possible by using a CNC automatic milling machine to precisely cut contours, fusing the wood and concrete forms together.

[Heroshot & Description]

Fluidity was the result of an exploration into robotic production. Our aim was to break traditional boundaries through using a modern production process, in this case robotically controlled Hot wire foam cutting. Fusion 360 was the platform we used to turn concept sketches into 3 dimensional products. When creating products in Fusion we had to make sure that it we used ruled surfaces for our profiles as this is a constraint of hot wire foam cutting.

[Disassembly view]

[Robotic Fabrication Reflection]

Robotic fabrication is a new methodology to approach industrial design. It brings many possibilities in every stage of design from ideation to product manufacturing or even to product selling system. There are many special advantages of robotic fabrication comparing with traditional manufacturing process, such as Mass customization, breaking the limitation of conventional manufacturing and complex morphology. Robots are very versatile machines, unlike traditional machines which are designed and made for certain task. It opens the gate of designing the process, and the final product is merely a result from it which can be many. Designers are given the ability to set up a system to create a series of objects, this is related with mass customization. By designing the process, products becomes more diverse than ever, not in the appearance but the content. Design is cross disciplines linking with many other fields, robotic fabrication allow designers to work with algorithms and programming. Robots are set up by programming it to performance various tasks. Algorithm levels up design from the very basics of the world. For example, surfaces are not only just aesthetically different variations, but they include a lot of mathematically different classes. In our case, ruled surfaces need to be identified by us to creating forms which can be produced with robotic hot wire foam cutting process. It becomes a handle of design concentrating us to a direction and by going into it there are many new possibilities waiting to be explored. Design with parameters is another way to use robotic fabrication. Things are surrounded by a number of factors affecting them and changing them. This is a new perspective to design with. In architecture, algorithms are used to simulate solar movement, voice spreading and so on to design a space for living. Here, robotic fabrication is the way to produce the shapes which are similar but with variations, on the contrast, traditional manufacture will be really hard to produce un- identical things such as paneling in this case. Parametric design is also suitable for industrial design. Products need to be optimized with the environment surrounding it and become more effective to serve its purpose. For another aspect, shapes may be optimized to reduce the material usage and its weight. In conclusion, robotic fabrication has its own advantages which are irreplaceable. It broadens industrial design to many new and challenging opportunities. Both form and function are benefited from this new approach of design.

[Fusion 360 Reflection]

Fusion 360 is the new generation software from Autodesk, it includes solid modeling, surfacing modeling, T-spline technology, 3 kinds of simulation, render and CAM together in one software. It is efficient for the whole design process from creating concept to manufacturing them out. In Fluidity project, Fusion 360 has gotten involved through the entire process. In the stage of concept exploration, the sculpture mode inspired us for the form of the bench. We used it loft two ends profile together and then manipulated the shape to fit ergonomically comfort. Loft feature under patch mode has sufficient control options to generate the surface for the Robotic foam cutting, such as profile sequence. Working with all the modeling modes together allows us to make both positive form and negative form (the tooling). The information we exported from fusion was applied directly in fabrication, it told us what are the volume and weight of the concrete casting. After modeling, simulation of fusion helps us to identify the max load and displacement of it. Cloud based collaboration system easier the team work and workplace change, so we donâ&#x20AC;&#x2122;t need to carry files every time. We used cloud sharing system to share files, although there was an issue before, once we shared the file the folder cannot be accessed (now, it has been resolved by the recent update). For the further improvement of Fusion 360, it may be better to change the body or surface split, so user can choose multiple lines to cut at one shot. The transparency of which is used to compare the change we made to the original sculpture surface can be set to be able to personalized, because we found sometimes it is really hard to see what is happening in details.

Roboto studio 2/11/2016