Fall 2020 - MArch Course: Machining with Material Agency (Nahmad Vazquez) by ucalgarySAPL

GROUP | 001 Ashley Hu / Caitlin Woods / Faraz Shapourzadeh Materialising with Machinic Agency

Group 001 | References Inspiration | Spiral Seasnail

Inspiration | Golden Proportion

Spiral seasnail has a logarithmic form made by calcium carbonate in an additive growing process. Each section has a round shape swept along a spiral path from a center to the last aperture. So the basic shape is not a ruled face, and inspiring from it for designing a hot wire cuttable form would be a new design challenge. Another challenge was how to translate a form made in an additive process into a subtractive language of design and fabrication.

Seashell spiral (aka Fibonacci spiral) form has goldern ration proportions of 1.618 in their dimensions. The traditional golden spiral expands each section’s width by the golden ratio with every quarter (90 degrees) turn.

DLPNG. [Conch Shell] . n.d. digital image, https://dlpng.com/png/6382908

Group 001 | References Inspiration | Spiral as a Parametric Twist

Inspiration | Parametric Texture

The form of seasnail’s sell has an axis in ended at the apex where the growth has started. In elevation, it has a sinusoidal wave bounded in a triangle. Exploring the form-making process could be the result of changing the parameters in this geometrical system.

Seasnail texture represents the sequences of its growth. It is related to the parameters such as time, thickness, dimensions, colors, etc. The design of furniture in this project attempts to translate it into a parametric texture able to be applied to the ruled surface and as combinatorial between nesting or assembling components.

Group 001 | References Inspiration | Precedents & Common Elements All design iterations have the following commonalities: shell curvature inspired, textured, and component-based. Each were inspired by the precedents below.

Shell Curvature Inspired

Textured

Component-Based

Nested

Group 001 | Explorations Digital Catalogue Catalogue | Swirl Component Designed so that components could be altered slightly to create four different furniture pieces. Base Component Design

Base Component Fabrication

Table

Combinations with Components Stool

Shelf

Rocking Chair

Group 001 | Explorations Digital Catalogue Catalogue | Nested Wave Using Maya, this design looked at optimizing the material with nesting. Base Component Design

Base Component Fabrication

Combinations with Components Bookshelf

Desk + Bench

Table

Bench Trio

Group 001 | Explorations Digital Catalogue Catalogue | Nested Swirl Furniture Combinations with Components

From two stock cubes of foam (block a + block b), three pieces of furniture can be built. Chair

Table

Shelf

A6 B3

Block A

Block B

B1 A1

A4 B2

Group 001 | Explorations Digital Catalogue Catalogue | Textured Hyperboloid Using Maya, this design looked at adding texture to a curved ruled surface. Base Component Design

Base Component Fabrication

Combinations with Components Side Table

Coffee Table

Stool

Bench

Group 001 | Explorations Digital Catalogue Catalogue | Shelled Component Another iteration on the textured, curved, ruled surface. Component can be arranged several ways. Base Component Design

Base Component Fabrication

Combinations with Components

Table I

Bowl Chair

Desk

Table II

Group 001 | Explorations Digital Catalogue Combinations with Components

Catalogue | Curved Component Base Component Design

Base Component Fabrication

Bookshelf

Group 001 | Explorations Digital Catalogue Catalogue | Component Bookshelf - Variations

Start and End Shapes

Profiles

Graph in Plan View

Module

Combination of Modules

Elevation

Group 001 | Explorations Digital Catalogue Catalogue | Component Bookshelf - Combinatorial Space

Combining Components by Mirroring

Combinatorial Surface between Rows

Changing Pointy Connections to Linear

Use of Texture as Joints between Components

Linear Connection to the Ground

Group 001 | Explorations Fabrication Catalogue Catalogue | Selected Pieces for Fabrication

Swirl Chair

Component Bookshelf

Bowl Chair

Group 001 | Explorations Fabrication Catalogue Component Bookshelf | Texture Development The original jagged texture would be too sharp to be effectively cut out by the robot. The following diagrams show some explorations used to soften the texture. As the bookcase uses the texture as a connection, the texture was developed here first before being applied to the other pieces. Using Attracting Points

Using Attracting Points

Smooth vs. Jagged

Using Phase Shift

Group 001 | Explorations Fabrication Catalogue Swirl Chair | Texture Development To unify the apperance of each iteration, the same texture is applied to the bottom and back.

Front

Bottom

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Texture Development The texture on the back of the component was designed in a way that single cut will cut out the texture on two nested components. Refer the the following pages to see the arrangement of the nested components. The same texture on the back is applied to the central hole.

Back

Bottom

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Preparation for Hot Wire Cutting Fabrication The component was redesigned to fit four pieces nested within the 9” cube and then arranged to reduce the number of cuts required to fabricate the components. The cone cut was designed to optimize the amount of material remaining, allow for a smooth transition between components, and allow for the crown shape from the texture to show at the top of the component.

Reduced Height

Original Assembly

Smoothed Cone Shape

Softened Texture

Revised Assembly

Cut Paths in a 9x9” Foam Stock

Group 001 | Explorations Fabrication Catalogue Cut Piece 1.1 Bowl Chair | Hot Wire Cutting Fabrication (Overview) Step 13: Rotate Cut Piece 1 & Arch Cut

Cut Piece 1

Step 1: Corner Cut

Step 9: Cone Cut Step 14: Seperate & Discard. Component A Complete Cut Piece 1.2

Step 2: Seperate & Discard

Step 10: Seperate & Discard Step 15: Place Cut Piece 2 & Flat Cut

Step 3: Flip Block & Corner Cut

Step 11: Shell Cut Step 16: Seperate & Discard Cut Piece 2.1

Step 4: Seperate & Discard

Step 12: Seperate. Produces Cut Piece 1.1 & 1.2 Step 21: Rotate Cut Piece 2.1 & Valley Cut

Step 17: Rotate Block & Cone Cut

Step 22: Seperate & Discard. Component C Complete

Step 18: Seperate & Discard. Component B Complete

Step 5: Cone Cut Cut Piece 2

Step 6: Seperate & Discard

Step 19: Place Cut Piece 2 & Shell Cut

Cut Piece 2.2

Step 23: Place Cut Piece 4 & Flat Cut

Step 7: Cone Cut Step 20: Seperate. Produces Cut Piece 2.1 & 2.2

Step 8: Seperate. Produces Cut Piece 1 & 2

Step 24: Seperate & Discard. Component B (#2) Complete

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Hot Wire Cutting Fabrication (splitting the block in two)

Step 1: Corner Cut

Ro b Re ot B lat as ion e

Step 2: Seperate & Discard

Step 3: Flip Block & Corner Cut

Step 4: Seperate & Discard

Cut Piece 2 (Step 19)

Cut Piece 1 (Step 9)

Step 5: Cone Cut

Step 6: Seperate & Discard

Step 7: Cone Cut

Step 8: Seperate & Set Aside Cut Piece 2

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Hot Wire Cutting Fabrication (cutting component A from piece 1)

Ro b Re ot B lat as ion e

Secure Block and Support Block to prevent movement during cut Cut Piece 1.1 (Step 13)

Cut Piece 1 (no move between Step 8 & 9)

Step 9: Cone Cut

Cut Piece 1.2 (Step 15) Affix Cut Portion of Support Block Before Next Cut For Stability Step 10: Seperate & Discard

Step 11: Shell Cut

Step 14: Seperate & Discard

Component A Complete

Cut Piece 1.1

Flat Side Down

Step 13: Rotate & Place Cut Piece 1.1 & Arch Cut

Step 12: Seperate & Set Aside Cut Piece 1.2

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Hot Wire Cutting Fabrication (cutting component B from piece 1)

Ro b Re ot B lat as ion e

Cut Piece 1.2

Flat Side Down

Step 15: Place Cut Piece 1.2 & Flat Cut

Component B Complete

Newly Cut Side Down

Step 16: Seperate & Discard

Step 17: Rotate Block & Cone Cut

Step 18: Seperate & Discard

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Hot Wire Cutting Fabrication (cutting B and C from piece 2)

Ro b Re ot B lat as ion e

Cut Piece 2.1 (Step 21)

Cut Piece 2 Cut Piece 2.2 (Step 23) Cut Piece 2.1

Step 19: Place Cut Piece 2 (From Step 8) & Shell Cut

Step 20: Seperate & Set Aside Cut Piece 2.2

Step 21: Rotate & Place Cut Piece 2.1 & Valley Cut

Step 22: Seperate & Discard

Step 24: Seperate & Discard

Component B (#2) Complete

Cut Piece 2.2

Add additional support for stability

Component C Complete

Step 23: Place Cut Piece 2.2 & Flat Cut

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Assembly Component B

Component C

Connection Option 1: Dowels Because the cut sequence for this chair was already so complicated, the sides of the component that rest against another component were left raw and, as such, no joint between the component was designed to be cut out. Drilling in holes for dowels is the most basic option for connecting between the components. This will hold the chair together but it is unlikely that the friction between the dowel and the foam will be enough to resist the lateral forces placed on the joint when someone sits on the chair.

Component A

Exploded Nesting

Component A

Component B

Connection Option 2: Plates The second option to connect between the components would be to use a plate connection. The issue with this connection is that it cannot be concealed within the form like the dowels can be. To preserve the aesthetics of the chair, the plate can be installed on the base of the chair. The plate connection should be more effective at resisting lateral forces.

Component C Arrangement

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Fabrication Troubleshooting

Bowl Chair | Fabricated Foam Prototype - Attempt 1

Issue: Instability The cut in Step 9 created two issues. The first was because it cuts deep into the support block, there was extra material to cut the blocks moved during the cut. This solution is simple, secure the blocks together and to the ground to prevent movement. The next was that the support block did not have sufficient surface remaining to for the remaining cuts to be balanced on. The solution here is to flip the support block and affix the cut piece back on for stability.

Issue

Solution

Issue: Unclear Directions In order to be able to nest this component within the foam block, there is a complicated series of cuts and rearrangements that must occur in the correct order and orientation. During the initial fabrication test, one crucial step was missed (the rotation in Step 17) which resulted the piece being discarded and only three of the four componenents were cut. The solution is to provide clearer directions.

Flat Side Down

Issue

Solution

Group 001 | Explorations Fabrication Catalogue Bowl Chair | Fabrication Troubleshooting Issue: Impercision The high level of percision for this design to work and for the pieces to correctly meet up was not possible with the set up used in the robot room. In order to achieve the correct cuts, the location of the uncut block has to be exactly measured then stabilized. This proceedure would need to to be repeated everytime the block had to be rotated or otherwise adjuted. If the position of the block was a little bit off, the cuts would end up lopsided. It was not practical to use this level of percision for this class as there were time restrictions and other groups that also needed to cut. Additionally, the cut sequence was still just as complicated as the first attempt and without access to the robot room to provide direction for how to align the pieces, mistakes were bound to be made. For these reasons, even on the second attempt the foam pieces did not quite match what was designed.

Illustration of Issue

Illustration of Designed

Bowl Chair | Fabricated Foam Prototype - Attempt 2

Group 001 | Explorations Fabrication Catalogue Component Bookshelf | Preparation for Hot Wire Cutting Fabrication

Nesting General Idea

Nesting in a cube (Prototype)

Nesting in a Cube

Nesting with ornamentations (Continuous Cutting Faces)

Group 001 | Explorations Fabrication Catalogue Component Bookshelf | Hot Wire Cutting Fabrication

Component Bookshelf | Fabricated Foam Prototype

Block B Block A

Cutting sequences

Block A: Cut 2

Block B: Cut 5

Cut 1: Splitting into two blocks

Cut 3

Cut 6

Cut 4

Cut 7

Group 001 | Explorations Fabrication Catalogue Component Bookshelf | Fabrication Troubleshooting Issue: Pointed Edges The initially proposed nesting was composed of pointed edges which would be difficult to achieve precisely with the hot wire cutter when reaching to the cube edges. The solution was to increase the length and providing tolerance fot errors.

Increasing tolerance for errors Issue: 180 degree twists The twisted faces required hot wire to be rotated 180 degree along the way. At first the paths were horizontal which caused hot wire frame to have clashes with supporting block. The solution was to rotate shapes 90 degree and make twists paths vertical.

Horizontal Position

Vertical Position

Group 001 | Explorations Fabrication Catalogue Swirl Chair | Hot Wire Cutting Fabrication After applying the texture, a joint was added to connect both pieces. The hot wire cutting fabrication steps are very similar to the original design, as this chair was designed with fabrication in mind.

Place Cut Block Piece 1

Cut

Cut Piece 1 Cut Paths in a 9x9” Foam Stock

Cut Piece 3 Joint Cut Piece 2

Separate Separate & Discard

Separate & Discard

Group 001 | Explorations Fabrication Catalogue Swirl Chair | Hot Wire Cutting Fabrication

Place Cut Block Piece 2

Cut

Cut Piece 1

Cut

Cut Paths in a 9x9” Foam Stock

Cut Piece 4

Cut Piece 2

Separate Separate & Discard

Separate & Discard

Group 001 | Explorations Fabrication Catalogue Swirl Chair | Assembly

Cut Piece 3

Cut Piece 4 Cut Piece 4

Gather Cut Pieces 3 & 4

Rotate Cut Piece 4

Connect

Completed Chair

Group 001 | Explorations Fabrication Catalogue Swirl Chair | Fabrication Troubleshooting

Swirl Chair | Fabricated Foam Prototype

Issue: Complicated Joint The initially proposed joint resulted in complicated cuts which created awkward seams. The solution was to create a simple curved joint which is located away from complicated seams.

Issue

Solution

Issue: Pointed Edges The initially proposed texture was composed of densely pointed edges which would be difficult to achieve precisely with the hot wire cutter. Also, pointed edges along the bottom surface would not be durable. The solution was to replace the texture with larger waves and ensure a flat bottom where the texture meets the ground.

Issue 1

Solution 1

Issue 2

Solution 2

Group 001 | Data Collection Swirl Chair | 3D Scanning Kinect for Windows Software Development Kit (SDK) v1.8

Processing 2.2.1

Settings optimized to remove background for 3D scanner generated mesh.

Settings optimized to remove background for 3D scanner generated point cloud.

Group 001 | Data Collection Swirl Chair | Point Cloud Troubleshooting

Swirl Chair | Comparing 3D Scanning Point Cloud to Rhino Model

Issue: Incorrect Origin Despite entering the end effector position coordinates from the robot teach pendant and the distance measured between the physical robot flange and the center of the Kinect end effector, the resulting location of the point cloud was not in the correct orientation or z location. As such, the point cloud had to be manually rotated and moved.

Issue

Solution

The 3D scanner point clouds generated by Kinect SDK is overlayed with the original 3D Rhinoceros model and the distance differences between the two objects are shown in a gradient (red - lower in z value and blue - higher in z value).

Group 001 | Data Collection Bowl Chair | 3D Scanning Kinect for Windows Software Development Kit (SDK) v1.8

Processing 2.2.1

Settings optimized to remove background for 3D scanner generated mesh.

Settings optimized to remove background for 3D scanner generated point cloud.

Group 001 | Data Collection Bowl Chair | Point Cloud Troubleshooting

Bowl Chair | Comparing 3D Scanning Point Cloud to Rhino Model

Issue: Missing Information At the time of the scan, the second attempt at cutting out the shelled bowl chair had not been competed, as such, only three of the four pieces were scanned. Additionally, the chair was designed with a hole in the center in order to create an interesting moment for the ornamentation to bridge the gap. The scanned components show the hole as is. To adjust for this, the point cloud was manualy manipulated to replicated the fourth piece and fill in the hole.

Issue

Solution

The 3D scanner point clouds generated by Kinect SDK is overlayed with the original 3D Rhinoceros model and the distance differences between the two objects are shown in a gradient.

Group 001 | Data Collection Component Bookcase | 3D Scanning Kinect for Windows Software Development Kit (SDK) v1.8

Processing 2.2.1

Settings optimized to remove background for 3D scanner generated mesh.

Settings optimized to remove background for 3D scanner generated point cloud.

Group 001 | Data Collection Component Bookcase | Point Cloud Troubleshooting

Component Bookcase | Comparing 3D Scanning Point Cloud to Rhino Model

Group 001 | Ornament Generation Component Bookcase | Ornament Variations

Reversing the List of Point Cloud

Combining Interpolation and Polyline

Changing the degree of bezier corners

Shifting the list of point clouds

Group 001 | Ornament Generation Component Bookcase | 3D Printing Sequence The final texture consists of straight lines connecting the nodes of the point cloud. First, the list of points was reversed, and then the points of the two list connected in the same order. The final result has a similar geometry compared to the twisted face behind it, and straight lines could exaggerate the language of the ruled surface used before in the process of form-finding. The sequences of printing have been ordered to start from the layers below to the one at front.

Sequances of 3D Printing (1/4 total time)

Sideview of the 3D Print Geometry Horizontal Orientation of Robot Nozzle

The Timeline of 3D Print path

Group 001 | Ornament Generation Bowl Chair | Ornament Variations The bowl chair was designed with a hole in the center with the intent that the ornament can act like a blanket that drapes over top and bridges that hole. The inaccuracy of the fabricated pieces (the first attempted cut) can be seen in the first variation. This variation would have been more successful if the cut pieces from the second attempt were scanned. The second variation with the straight lines was more forgiving with the imperfections from the scan and bridged over the hole nicely. Because the 3D printing was not actually completed, troubleshooting for this design was not done; however, the success of bridging over the hole would be dependent on the ability for the 3D printing material to remain suspended in air as it is fabricated.

Group 001 | Ornament Generation Swirl Chair | Ornament Variations When 3D printed, the ornament is intended to drape over the chair like a blanket.

Group 001 | Ornament Generation Swirl Chair | 3D Printing Sequence

Group 001 | Ornament Fabrication Swirl Chair | 3D Printing Troubleshooting Issue: Pattern Extending into Foam The 3D printing pattern generated with Grasshopper from the 3D scanned point cloud extended into the front of the hot wire cut foam chair. To resolve the issue, the points which extend beyond the front of the chair was removed.

Issue

Solution

Group 001 | Bibliography

Images: Djmilic (2017, October 17). Layered Cut Matryoshka Dolls. Retrieved November 29, 2020, from https://www.istockphoto.com/photo/layered-cut-matryoshka-dolls-3d-gm862477974-142955989 Fragkou, V. (n.d.). Coral [Ceramic sculpture for the wall 87 x 40 x 14 cm]. Retrieved November 26, 2020, from http://vassofragkou.blogspot.com/p/sculpture.html G. (2016, December 21). Casting Mass [Casting Mass. First Year. Borhani Studio. Nick Houser.]. Retrieved November 26, 2020, from https://www.instagram.com/p/BOOMkp5lz-5/ H. (2012, April 6). Repetition n rhythm [Digital image]. Retrieved November 26, 2020, from https:// www.deviantart.com/happylemony/art/repetition-n-rhythm-295169334