Digital Fabrication Portfolio.2023-2024

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Digital Fabrication Portfolio

2023-2024

Zahra Cheragh Nia

Zahra.Cheraghnia@mail.polimi.it

I am a computational designer with a background in architecture and experience in digital fabrication, additive manufacturing, and robotic fabrication. Utilizing advanced design and fabrication techniques, I develop innovative solutions for a wide range of projects.

Table of Content

Pick & Place 01 02 03 05 04

Additive Manufacturing

3D Printing Plastic and Clay

Graph-Based Mesh Panelization

CNC Cut - Augmented Reality

Incremental Sheet Forming

Robotic Fabrication

Robotic Assembly

Soft Robotic Solar Facade

Soft Pneumatic Actuators

- 01 -

Additive Manufacturing

3D

Printing Plastic and Clay

SMAC Summer School

Supervisor: Stefano Giovacchini

Software: Rhino - Grasshopper

During this summer school, we delved into additive manufacturing using both clay and plastic, exploring their possibilities, limitations, and various applications. I developed two projects—one for clay and one for plastic— that initially followed the same concept. However, after evaluating the unique characteristics and limitations of each material, I made specific modifications to adapt the designs. Both systems were developed with the potential to function as facade systems or integral components of one.

Designed Geometry

Contouring

Tool Path planes

Process Simulation

Tool Path Creation

Calibrating the End Effector

Program Simulation

Vision for the Future

Pattern variations

Parametric Pattern Algorithm

- 02 -

Graph-Based Mesh Panelization

CNC Cut - Augmented Reality

Final Project - IndexLab

Supervisor: Pierpaolo Ruttico

Software: Rhino - Grasshopper

This project explores advanced fabrication methods for complex shading elements on building facades, integrating algorithmic programming, robotics, and augmented reality (AR). By developing a digital workflow that unifies design, fabrication, and performance analysis, the research demonstrates how robotic fabrication and AR can enhance precision, efficiency, and sustainability.

Through a case study, the project shows that these technologies streamline the design-to-fabrication process and improve the adaptability and performance of architectural facades, laying the groundwork for future innovation in complex architectural systems.

1. Base Surface

Rationalization

Offsetting

Clustering

5. Panelization 6. Optimization to Find Maximized Stiffness and Overlap Between the Two Layers

Connections

1.Folding Lines of the panels

2.Rivet connection Between Layers

3.Final connected module

1.Base Panel

Labelling

2.Panel Labelling

3.Surface Labelling

4.Angle Labelling

1.Outline of the Panel

Documentation

Holes

Documentation

Setting Up Augmented Reality Using Fologram

- 03 -

Incremental Sheet Forming

Robotic Fabrication

Final Project - IndexLab

Supervisor: Pierpaolo Ruttico

Software: Rhino - Grasshopper

This project explores advanced fabrication methods for complex shading elements on building facades, integrating algorithmic programming, robotics, and augmented reality (AR). By developing a digital workflow that unifies design, fabrication, and performance analysis, the research demonstrates how robotic fabrication and AR can enhance precision, efficiency, and sustainability.

Through a case study, the project shows that these technologies streamline the design-to-fabrication process and improve the adaptability and performance of architectural facades, laying the groundwork for future innovation in complex architectural systems.

Tool Path Generation

Initial Geometry

Incorporating Small Planar Surfaces

Identifying the Different Curvatures

Rationalization

Tweening through the boundary curves

Typology 1

Typology 2

Second Set of Toolpath

1. Starting Point
2. Incrementing Process
3.Final Point
Process Simulation

On-site Assembly

Fixture System Assembly

End Effector Assembly

Calibration Process

- 04 -

Pick & Place

Robotic Assembly

Robotic Programming - RWTH University

Instructors: Ethan Kerber

Software: Rhino - Grasshopper - KUKA|prc

Introduction to Robotic Programming” course by RWTH Aachen University offers a foundational overview of key concepts in robotics, focusing on kinematics, dynamics, and control systems. Through this course, I gained essential skills in robotic programming, learning how to effectively manage and control robot movement using tools like ROS (Robot Operating System). The course emphasized practical application, allowing me to apply theoretical knowledge to real-world scenarios. By the end of the course, I developed a strong understanding of robotic principles and honed my ability to program and control robotic systems, preparing me for more advanced work in the field of robotics.

Start Position

Pick up Approach Position

Gripper

Pick up Position

Pick up Retract Position

Assembly Approach Position Assembly Position

Assembly Retract Position Pick Up

Position

Open Gripper
Open Gripper

- 05 -

Soft Robotic Solar Facade

Soft Pneumatic Actuators

Adaptive Facade Studio - IndexLab

Supervisor: Pierpaolo Ruttico

Software: Rhino - Grasshopper

Solymorph is an integrated kinematic building facade designed to optimize energetic behavior and architectural expression through individual modules. Installed on an existing library facade at Politecnico di Milano, Lecco, this case study demonstrates significant improvements in electricity generation compared to static photovoltaic systems.

The project highlights the potential for energy savings in various climates and aims to drive advancements in sustainable building design by leveraging soft robotics and artificial intelligence. This innovative approach contributes to developing energy-efficient facade solutions for both new constructions and existing buildings.

System Breakdown

0. Existing building façade
1. Main steel frame
2. Steel anchor rods
3. Cable net structure
4. Soft robot assembly 5. Hexagonal PV-panels

Supporting Frame

Surface Generation

Cable Structure

Edge Anchors

Soft Robots at Nodes

Solar Panels

Solar Radiattion Analysis

Structural Analysis

1. Existing Structure I-Beam

2.Main Support Beam Heb160

3. L-Section 150x12 Top Sliding Beam

4. Module Steel Frame Hss 160x80x5

5. Rollers

6. Steel Rod Od73

7. U-Section 150x80 Bottom Sliding Beam

Connection to The Structure

Cable Connection To The Building

Soft Robot Unit Assembly Node Assembly

1. Support rod node 73mm with 3 20mmø holes

2. 20mm thick 242mmø steel connecting ring node 73mmø internal diameter

3. Steel no hub coupling 73 mmø

4. Cable connector

a)The arrangement of

a central point

5. Combined cable

1. 10mm thick, 100mm long steel support legs

2. 2mm thick aluminum universal joint with aluminium plate

3. Silicon actuator

5. Junction box

7. Hexagonal PV panel

4. Steel connector

6. 1mm aluminum sheet

combined cables at
b) ø250mm aluminum disc supported by the OD73 steel rod suspended from the frame
c) Aluminum cantilever
Silicon Actuator
Silicon Actuator Rotation

18mm Hollow Chamber for Cables

10mm Thick Silicon Top

2mm Thick Al Universal Joint to Stabilize

The Actuator And Restrict Z-Axis Movement

Silicon Actuator with 3mm Thick Valve

Universal Joint

10mm Thick Silicon Base

Designed Mold for the Physical Prototype

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