Interactive 3D Printing
Project Information
Institution University of Sydney + RobArch 2016
Instructor(s) Alexandre Dubor, Dagmar Reinhardt, Kate Dunn, Martin Bechthold, Kevin Hinze,
Susannah Alarcona
Collaborator(s) William Ellsworth, Steve Fuchs, Samuel Lewis
Course Date Spring 2016
Workshop Abstract
Robotic Fabrication processes enable designers and architects to explore the boundaries between digital and material worlds. Beyond optimization criteria or parametric design, new design strategies such as generative design and collaborative design are enabling new ways of approaching material exploration through robotics. Typically, the outcomes of a fabrication process are predetermined, however, with the introduction of sensors, design and fabrication process may be interrupted by real-time feedback. This workshop explores the potential for creative practitioners to adopt robotic fabrication processes augmented with the introduction of sensors. Using an inexpensive toolbox of sensors useful for digital fabrication, participants in the workshop will construct and integrate sensing apparatus into the 3D Printing process to explore the role of material feedback in an on-going design process.
The workshop used the following objectives; to test applications of parametric modeling, robotics and additive manufacturing for innovation of new construction techniques; to alternate structures using biomorphic design to create scalable, self supporting structures that can be 3D printed using sustainable materials; to employ environmental conditions (like sound) to inform robotic deposition process, i.e. focus on dynamic processes where information continuously changes; and to test material response to gravity/density/texture/structural integrity, and aesthetics.
Showcased here are approaches towards the 3D printing of hexagonal wall tiles in modular groups that rethink the wall.
Fig. 01
Fired Print - View 1
Fig. 02
Fired Print - View 1
Fig. 03
Fired Print - View 1
Fig. 04
Fired Print - View 1
Developing Form
Our intent was to develop a grasshopper script which acted as a framework for all future tests and explorations. Since our goal was to test real time interactive opportunities, we developed a series of hexagonal tiles which could cope into an adjacent hexagonal tile. These tiles could anticipate subtle changes and physically support those changes with it’s proximity. This definition allowed us to tailor the form of the ceramic print to different iterations quickly and effectively. See Fig. 05 for an example of these scalar relationships.
Part I
The definition works by declaring a base point, then create a series of circles which radiate this base point. These circles become the framework for the hexagonal panels and scale relative to the central point of each circle.
Part II
Each circle is divided into 6 points which interpolate to create a curve. This curve acts as the base and first layer of the print. A second series of 6 points is elevated in the Z plane and is controlled by 6 randomized scalar relationships as well. These 6 points are then interpolated to create the upper curve. The upper curve acts as the maximum upper limit of the print.
Part III
The base curve and upper curve are then infilled with a series of tween curves which act as individual layer curves. By taking full control over all these curves, we have essentially created our own tool paths which allow the designer to design beyond conventional contoured tool paths. See Fig. 01-04 for tool path variability examples.
Part IV
All curves are then organized, divided into points, then fed into a custom script to create g code. This g code can be fed into any 3D printer with slight adjustments to the header and footer of the code depending on manufacturer. The full definition can be found below, see Fig. 06.
Fig. 05
Scalar Coping
Fig. 06
Grasshopper Definition
Testing Form
Our first series of prints tested a single hexagonal tile. We wanted to make sure the variable height was calibrated accurately and the extrusion pressure could facilitate ceramic walls of adequate thickness.
Fig. 07
Terra Cotta Extrusion
Fig. 08
Variable Height Test
Fig. 09
Extrusion Pressure Artifact
Fig. 10
Scale Study