brick geometries: 5-axis additive manufacturing for...
TRANSCRIPT
BRICK GEOMETRIES: 5-AXIS ADDITIVE MANUFACTURING FOR ARCHITECTURE
Building Technologies profoundly affect architectural design. Digital Technologies offer computational models to analyze structure, articulate design intention and develop creative production techniques. The means, methods and exchange of building construction knowledge is advancing on many fronts. However, traditional material systems still dominate the architectural pallet. Glass, steel, concrete, clay and wood are cut, shaped, bent and assembled in increasingly complex ways. It is the architect’s job to compose and orchestrate these systems. With this knowledge of production, materials and structure, the architect can integrate the skill and intelligence at the core of architecture.
Brick Geometries interrogates how digital technology can contribute to 6000 years of knowledge in architectural ceramics. Historically associated with craft-based manufacturing or high-volume industrial production, novel ceramic forms and innovative brick structures are typically developed from a ready-made, already existing selection of building components. This research proposes a new approach to the fabrication process of ceramic materials, constructing the tools and developing the material technology to explore 5-Axis Additive Manufacturing as a function to rethink construction methods and geometric form. The project exploits material effect of the clay body, design computation and software manipulation to innovate on what is becoming a 21st century craft.
CONTRIBUTORS
OPEN-SOURCE CREDITS
SPONSORS AND THANKS-TO
Brandl, Jessica: http://jessicabrandl.com
Code Without Frontiers, GSD Student group: https://www.facebook.com/CodeWithoutFrontiers
Czibesz, Brian: http://www.bryanczibesz.com
Johnson, Brandon. UWM BSAS Architecture
Melenbrink, Nathan. GSD MDes
Park, Daekwon. GSD DDes: http://daekwonpark.com
Smith, Michael J., GSD MArch: http://www.rukamathusmith.com/rukamathu-smith
Keep, Johnathan: http://www.keep-art.co.uk/Self_build.html
Marlin Firmware: http://www.marlinfirmware.org/index.php/Main_Page https://github.com/MarlinFirmware/Marlin
World’s Advanced Saving Project (WASP): http://www.wasproject.it/w/en/ http://www.personalfab.it/en/downloads-2/download-info/ldm-wasp-extruder/
Bechthold, Martin. Professor of Architectural Technology Harvard University, Graduate School of Design, Material Processes and Systems Group @ Harvard GSD: http://research.gsd.harvard.edu/maps/
Asensio Villoria, Leire. Lecturer in Architecture Harvard University, Graduate School of Design Thesis Advisor
Harvard University Graduate School of Design Fabrication Lab Staff Vroman, Rachel. LeGeyt, Burton. Hansen, Christopher
Bitton,Joëlle.GSDDDes:http://joelle.superficiel.org/
Blough, Tom. Senior Staff Engineer, Mechanical, Wyss Institute, Harvard University Medical School
Contributors
open-sourCe Credits
sponsors and thanks-to
FORMAT SUMMARY
1 PAGE SPREADFormat Summary
This area includes notes written by the author to describe each slide for the 30 minute presentation, highlighting critical moments in the research, raising items for discussion.
This area shows the original images, diagrams and text as displayed during the slide presentation beginning at 10:00, Jan. 19, 2016.
Image Sources (books, websites, photographers and authors) cited in this area.Placement of citations correspond to the placement of images above.If no citation is listed, the drawing or photograph belongs to the author.
Theories guiding the goals of research investigated in this thesis.
2 PAGE SPREADMaterial Technologies
MATERIAL TECHNOLOGIES
Architectural Technologies
In general, we know that technology effects the state of architecture, the designer and the idea of craft in the 21st century:--System Design--Material Technology--Manufacturing Technology
Material & technology are directly connected to design potential. All have an impact on Architectural Form
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Quest for Sustainable Customization: (an) agency of architecture
1.2.4. Master builder
In the digital age of mass customization new possibilities are offered to architects for regaining what one might refer to the ancient role of the master builder. In this sense, Filippo Brunelleschi can be considered the quintessence of the master builder, being an innovative architect, builder, product engineer, and material scientist – as the construction of the dome of S. Maria del Fiore in Florence clearly demonstrates (fig p.27).
Fig. 1-4:Filippo Brunelleschi as master builder (source: Kieran).
SYSTEM DESIGN + STRUCTURAL FORM
MATERIAL SYSTEM + FABRICATION TECHNOLOGY
MANUFACTURING + EXPRESSIVE FORM
Stuttgart 2014
Barcelona, Spain, 1904
Paris c.1900source: Andreani
“Mannheim Multihalle.” WAM. Accessed September 10, 2015. http://www.worldarchitecturemap.org/buildings/ mannheim-multihalle. “ICD/ITKE Research Pavilion 2013-14.” Achim Menges. Accessed September 10, 2015. http://www.achimmenges. net/?p=5713.Boake, Terri Meyer. “ Innovative Connections.” SSEF. Accessed December 2, 2015. http://www.tboake.com/SSEF1/cast. shtml.
Andreani, S. (2013). Stefano Andreni, “[R]evolving Brick: Informed Design and Robotic Fabrication Workflow for Strategic and Sustainable Mass Customoization of Complex Ceramic Building Sytems” Master in Design Studies Technology Concentration, Harvard University Graduate School of Design, 2013.
Ceramic Medium
Ceramics are the medium used to explore this agenda --as inspiration for material-based research: ---looking at system design ---developing expressive form----for structure, light & experiential effect
This Thesis investigates the design of ceramic structures in the light of industrial production.
INDUSTRIAL PRODUCTION + CRAFT
Barcelona, Spain, 1904
Terrassa, Catalunya, 1909
“The Best of Barcelona - Barcelona Blonde.” Barcelona Blonde. Accessed September 5, 2015. http://barcelonablonde. com/the-best-of-barcelona/. “Technology: The Catalan Vault – A Historical Structural Principle with a Bright Future | DETAIL Inspiration.” Technology: The Catalan Vault – A Historical Structural Principle with a Bright Future | DETAIL Inspiration. Accessed July 20, 2015. http://www.detail-online. com/inspiration/technology-the-catalan-vault- %E2%80%93-a-historical-%C2%ADstructural-principle- with-a-bright-future-106565.html
2 PAGE SPREADCeramics in Architecture
A brief history of a centuries old building element.
CERAMICS IN ARCHITECTURE
Ceramic History (in architecture)
Formal architecural ceramic elements appear as early as 2600 BC. Custom 3D reliefs appeared sometime around 600 BC.
However, Ceramic production today is as it was for almost 5000 years. However, the digital revolution is changing how er approach and look at the medium in the 21st century.
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+4000 YR OF REFINEMENT
Luxor, Egypt, 20th c.
Danube Delta, 21st c.
Babylon, Mesopotamia, 604-562 B.C. Babylon, Mesopotamia, 604-562 B.C.
Glazed Brick 2600 B.C
© ITC-AICE, 2013
PRIMAL EXAMPLES
Adobe
6.000 B.C.Glazed Brick with relief.
600 B.C
Fired Brick
3.000 B.C. Glazed Brick 2600 B.C
Italy, 21st c.
“IBL: Naturalmente Casa.” IBL Spa. Accessed September 3, 2015. http://www.iblspa.it/. Soare, RomaniaDanubeDelta. digital, 2,272 × 1,712 pixels. Available from: Wikinedia Commons, https:// commons.wikimedia.org/ wiki/File:RomaniaDanubeDelta_ MakingMaterialForCOnstructing0002jpg.JPG (accessed September 3, 2015).“THaWS Project – Start of the week survey at Kom el Hetan.” Kristian Strutt. Accessed September 2, 2015. https:// kdstrutt.wordpress.com/page/6/.
“Panel: striding lion [Excavated at Wall of Processional Way, Babylon, Mesopotamia]” (31.13.2) In Heilbrunn Timeline of Art History . New York: The Metropolitan Museum of Art, 2000–. http://www.metmuseum.org/toah/ works-of-art/31.13.2. (October 2006)
Mira, Javier. “Ceramics for Architecture. FUNDAMENTALS.” Lecture, September 3, 2015. https:// performativeceramicscreens.files.wordpress. com/2013/07/javier-mira-ceramic-for-architecture-ok. pdf.“Visiting the Ancient City of Babylon - Ancient History Et Cetera.” Ancient History Et Cetera. 2014. Accessed January 26, 2016. http://etc.ancient.eu/2014/11/17/visiting- ancient-city-babylon/.
Ceramic History (in modern architecture)
Ceramics Production has an effect on the architectural result.
-Where craft production is often tied to a particular place and set of local knowldge, location is not as important in a global economy (as is the case today); knowledge is easily transferred across continents.
-Industrial economy (today) inspires uniform, mass-produced design elements; as Corbu elluded to in the 1930s
-In all cases, architectural ceramics prove to be a very versatile medium for the architect’s design pallet
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DIGITAL DESIGN + STRUCTURAL FORM
MACHINE AESTHETIC
EXPRESSIVE FORM
Zurich, Switzerland, 2012
Poissy, France, 1931
Buffalo, NY, United States, 1896
Aichí, Japan, 2005
Mainz, Germany, 2010
Barcelona, Spain, 2005
Zaragoza, Spain, 2008
“Cerámica Cumella.” Cerámica Cumella. Accessed October 26, 2015. http:// www.cumella.cat/quefem.htm. “Cerámica Cumella.” Cerámica Cumella. Accessed October 26, 2015. http:// www.cumella.cat/quefem.htm. “Cerámica Cumella.” Cerámica Cumella. Accessed October 26, 2015. http:// www.cumella.cat/quefem.htm. “A Daily Dose of Architecture.” : Today’s Archidose #453. Accessed October 3, 2015. http://archidose.blogspot.com/2010/10/todays- archidose-453.html.
Breitfuss, Klemen. “Free-form Catalan Thin-tile Vault, Zurich, Switzerland.” BLOCK Research Group. Accessed January 26, 2016. http://www. block.arch.ethz.ch/brg/project/free-form-catalan-thin-tile-vault. Sullivan, Mary Ann. “Images of Villa Savoye by Le Corbusier.” Images of Villa Savoye by Le Corbusier. 2006. Accessed September 3, 2015. https:// www.bluffton.edu/~sullivanm/france/poissy/savoye/corbu9.html. Sullivan, Mary Ann. “Images of the Guaranty/Prudential Building by Louis Sullivan.” Accessed January 26, 2016. https://www.bluffton. edu/~sullivanm/newyork/buffalo/sullivan/guaranty.html.
3 PAGE SPREADCeramic Technologies
The most advanced architectural ceramic technologies available today.
CERAMIC TECHNOLOGIES
Contemporary Direction + Method
Innovative architecture using ceramic components seems to use two basic component assemblies:
-Method
-Pattern
Lisbon, Portugal, 2011
Barcelona, Spain, 2010
France / Netherlands, 2013
Amsterdam, 2013
ARRANGE BY PATTERNARRANGE BY METHOD
Lutyens, Dominic. “Out on the Tiles: Ceramic Architectural Facades.” Articles We Keep You Informed with Our News. 2013. Accessed July 7, 2016. http://www. architonic.com/ntsht/out-on-the-tiles-ceramic-architectural- facades/7000794.
Lutyens, Dominic. “Out on the Tiles: Ceramic Architectural Facades.” Articles We Keep You Informed with Our News. 2013. Accessed July 7, 2016. http://www. architonic.com/ntsht/out-on-the-tiles-ceramic-architectural- facades/7000794.
Oswald, Samantha. “Techne and Poiesis: 2013-06-09.” Techne and Poiesis: 2013- 06-09. Accessed July 7, 2015. http://techneandpoiesis.blogspot. ca/2013_06_09_archive.html.
Rietveld, Gerrit. “Bricking Pattern.” Bricking Pattern. Accessed July 8, 2015. http:// www.the-interiordesign.com/en/design-data/bricking-pattern/326.
Contemporary Direction + Method
To clarify:
-Arrange by Method--where identical components are designed with a smart geometry supporting an articulated assembly
-Arrange by Pattern--where 2 or more components have a geometrical relationship with changes in color, opacity, similar points of relationship and are interchanged according to the will of the designer
Digital technology can have a profound effect on industrial production to contribute more design options for our architectural pallet.
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DESIGN PATTERN DIAGRAM
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ARRANGE BY PATTERNARRANGE BY METHOD
Manufacturing Technology
I’ve been fortunate to have contributed on two projects that combine digital design and industrial production technologies.
-In each case, machines and digital fabrication technology hadasignificantinfluenceonthefinaldesign.
However, the manufacturing technologies employed to producethefinalproductshaven’t changed. In the case studies I encountered, traditional machines were more often than not used to manufacture digitally designed architectural components.
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FORWARD DESIGN + TRADITIONAL MANUFACTURING
United States c.19th c.
Valencia, Spain, 2014
Cambridge, MA, United States, 2014
“History.” Team Fritz Clay Roof Tiles. Accessed July 30, 2015. http://www.clayrooftiles. org/history.htm.
“Ceramic Shell @ Cevisama 2014.” MaP S. 2014. Accessed July 7, 2015. http:// research.gsd.harvard.edu/maps/portfolio/4936/. copyright: Harvard University
Maggie Janik [Harvard GSD]. Chromosomes. Dec. 2014. Source: photographer.
6 PAGE SPREADIndustrial Technology
A short description about the state of industrial ceramic production.
INDUSTRIAL TECHNOLOGY
Forming Methods
Nearly all manufactured Ceramics are produced by a few primary forming methods:-Slip Casting-Extruding-Dry Pressing----each type facilitates a mixed assement of geometric complexity, permeability and productivity, among others.
I have highlighted the attributes that most greatly effect the research I am presenting today such as:--production cost--avg moisture--shrinkage
Most of my work focused on extrusion technologies (as will belaterdefined).
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source: Händle
Ceramic Shaping Parameters by Technique
Specific production costs high low medium
Plant complexity high low medium
Automation level low high high
Productivity low high very high
Article thickness highly varilable variable constant
Article size large medium small
Geometry of shaped article complex quite complex simple
Firing ability low medium high
Glazing ability low low high
Surface permeability low low high
Drying energy consumption high low high
Drying ability low low high
Shrinkage after firing high medium low
Mould/die porosity yes no no
Mould/die material rigid rigid rigid or elastic
Green deformability high medium low
Green density low medium-high high
Shaping energy consumption low medium high
Duration of shaping process high medium low
Avg. moisture after shaping 18% by wt. 17% by wt. 5% by wt.
Avg. moisture before Shaping 28% by wt. 17% by wt. 5% by wt.
EXTRUDING DRY PRESSINGSLIP CASTING
Händle, Frank. Extrusion in Ceramics. Berlin: Springer, 2007.
Existing Digital-CeramicResearch
Existing research combining ceramic manufacturing and digital technologies with building-scale applications deploy the three methods listed above:-Slip Casting-Extrusion-and Pressing (moist & dry)
As reference, I am deploying extrusion in my research presented today: a piston extruder supplying a smaller, more nimble auger extruder.
In any case, 3D printing ceramics is relatively new to the craft.
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Ceramic Building Industry: between past and future
interlocking geometries side elevation
CERAMIC UNITS PROTOTYPES
serialised mass customization plan
Fig. 2-86: Flowing Matter, Andreani, del Castillo and Jyoti, Harvard GSD (source: Harvard DRG).
ADVANCED DESIGN + PRODUCTION
Cambridge, MA, 2012
Girona, Spain, 2009
Oisterwijk Netherlands, circa 2012
Andreani, S. (2013). Stefano Andreni, “[R]evolving Brick: Informed Design and Robotic Fabrication Workflow for Strategic and Sustainable Mass Customoization of Complex Ceramic Building Sytems” Master in Design Studies Technology Concentration, Harvard University Graduate School of Design, 2013.
Stein, Joshua G. “Projects :: Tectonic Horizons.” Data Clay. Accessed January 26, 2016. http://www.data-clay.org/projects/Tectonic Horizons/ index.html.
“Cerámica Cumella.” Cerámica Cumella. Accessed October 26, 2015. http:// www.cumella.cat/quefem.htm.
Digital Manufacturing Methods
Some of the more advanced precedents make extensive use of digital technologies, combining:-Material Science-Computational Science-and established Craft and Industrial Process
**Ceramic Craft is migrating into the hands of the digital designer; especially as the next generationsbecomemorefluidwith machine technologies.
This thesis research investigates how digital technologies can help architects:
-Create elegant architectural solutions with advanced technology.
-Contribute to manufacturing Technology, with the knowledge about what is possible with the means of the craftsmen employed.
-*Reiteratethedefinitionofa 21st century craftsmen by uncovering ways to exploit material as a digital craft.
DIGITAL FABRICATION
COMPLEX GEOMETRIES
Harrow, Del. “Projects :: Bone Scaffolding.” Data Clay. Accessed January 26, 2016. http://www.data-clay.org/projects/Bone Scaffolding/index. html.
Russo, Rhett, and Katrin Mueller-Russo. “Projects :: Flabella.” Data Clay. Accessed January 26, 2016. http://www.data-clay.org/projects/ Flabella/index.html.
Harrow, Del. “Projects :: Bone Scaffolding.” Data Clay. Accessed January 26, 2016. http://www.data-clay.org/projects/Bone Scaffolding/index. html.
Russo, Rhett, and Katrin Mueller-Russo. “Projects :: Flabella.” Data Clay. Accessed January 26, 2016. http://www.data-clay.org/projects/ Flabella/index.html.
ManufacturingMethods
Typically, ceramic manufacturing involves a series of combined methods:
-Craft based manufacturing-Digital technologies (primarily for die, mold and prototype making)--Often deploying Product-Specificmachines
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[R]EVOLVING BRICK
Figs. 2-18, 2-19:Two machines operating on the revolving table principle. A vertical plunger forces clay into moulds mounted in the table which revolves to put the next set of moulds under the plunger (source: Campbell).
CRAFT-BASED MANUFACTURING
MANUFACTURING METHOD
PRODUCT-SPECIFIC MACHINES
“CNC Router and Machining Centers BMG 500/600 - Staircase Production .” HOMAG Group. Accessed January 26, 2016. http://www.homag.com/en-en/products/productdatabase/ homag/Pages/bmg500_stairs.aspx.
Kaltenbach, Frank. “Thousand-Year Sheen.” Detail, Vol. 2011. 466-76.
Andreani, S. (2013). Stefano Andreni, “[R]evolving Brick: Informed Design and Robotic Fabrication Workflow for Strategic and Sustainable Mass Customoization of Complex Ceramic Building Sytems” Master in Design Studies Technology Concentration, Harvard University Graduate School of Design, 2013.
Existing 3D Printing Ceramic Technology
Fortunately, ceramic material properties (grain, adhesion properties, mailability, reaction to moisture, etc) lends itself to 3D printing technologies.
Existing methods deploy the powder-bed method to either bindorsinterafineceramicdust.
There is a small group of people experimenting with ceramic extrusion technology but not much is published (outside of blogs and misc websites). Knowledge of the subject is still limited but information exists on the technology.
Most importantly:*ceramic material properties fitwithinframeworksoftheseexisting technologies.
NOTE: LSL (laser selective sinter) --production at Shapeways.FDM (fused deposition modeling)--most applicable for industrial production(speed, scale, accuracy & cost)
Ejection Nozzle
Deposited Layers(modeled part)Control Surface
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...AXONOMETRIC DIAGRAM LAYER DEPOSITION
Ejection Nozzle
Deposited Layers(modeled part)
Control Table
Laser Sinter
Printer PowderPart Part
Build Plate Build Plate Drops
Roller / Powder Rake
Machine Head PowerSource
POWDER BED X,Y,Z EXTRUSION
DIGITAL PRODUCTION / 3D PRINTING
Machine-Material Manufacturing Design
To advance ceramic extrusion 3D printing technologies, it was important to gather a small but more informed understanding of larger scale extrusion manufacturing.
Machine science and material science have a profound effect on the production of architectural components. Basic Column Extrusion Machinery
Basic Piston Extrusion
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Ceramic Building Industry: between past and future
The six primary clays mined and used in the United States are ball clay, bentonite, common clay, fire clay, fuller’s earth and kaolin. Ball clays, common clay and shales, fire clays and kaolin are the primary contributors to building materials including bricks, firebricks, and structural and regular tiles. Fuller’s earth is used in the production of Portland cement. Of all clays used in the United States, 64% are used in construction.4
The three principal forms of clay employed for manufacturing building components can be found at different levels underground:
- Surface Clays: could be the upthrusts of older deposits or of more recent sedimentary formations. As the name implies, they are found near the surface of the earth.
- Shales: clays that have been subjected to high pressures until they have nearly hardened into slate.
- Fire Clays: usually mined at deeper levels than other clays and have refractory qualities.
The manufacturer minimizes variations in chemical composition and physical properties by mixing clays from different sources and different locations in the pit. Chemical composition varies within the pit, and the differences are compensated for by varying manufacturing processes. As a result, brick from the same manufacturer will have slightly different properties in subsequent production runs. Further, brick from different manufacturers that have the same appearance may differ in other properties.
Fig. 2-3: (opposite)
Classification of the ceramic products by applications (source: Reh).
Fig. 2-4:Clay powders (source: scmwaterproofporous.blogspot.com).
Length
DIA
Die
Ram Velocity
Extrudate Velocity Extrudate
Barrel
Ram
Die entry region
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AXONOMETRIC DIAGRAM... PISTON EXTRUDER
Händle, F. Extrusion in Ceramics
MACHINE SCIENCE MATERIAL SCIENCE
source: Andreani
Andreani, S. (2013). Stefano Andreni, “[R]evolving Brick: Informed Design and Robotic Fabrication Workflow for Strategic and Sustainable Mass Customoization of Complex Ceramic Building Sytems” Master in Design Studies Technology Concentration, Harvard University Graduate School of Design, 2013.
Händle, Frank. Extrusion in Ceramics. Berlin: Springer, 2007.
“Ceramic Roller Extruder.” Xiangtan Weida Electrical and Machinery Manufacture Co.,LTD. Accessed January 26, 2016. http://www. tilemachinery.com/product/ceramic-roller-extruder-2/.
Diagram by Author
4 PAGE SPREADDesign Argument
Why 3D printed ceramic extrusion.Why the research is valuable.What the research can contribute to archtectural construction technology.
ARGUMENT
Argument
I had to ask:-Why does the brick need to be manufactured with 3D printing technology?-Why wouldn’t this item be produced with other proven manufacturing methods?
Essentially, the brick has a performative aspect embedded into its geometry.-mass customization (most obvious arguement)-environmental performance--heat transfer--light-connection detail / interface-or simply visual articulation for experiential effect
I used this thesis to exercise my ideas for structural performance and visual / experiential effect.
NOVEL GEOMETRY
Manufacturing Typology
Screen shows on left a brick I printed but had quoted by the GSD FabLab. At right is an image of a block I used to investigate the fabrication parameters of a system I would later design to test toolpaths for a 6-Axis robotic arm.
In any case, no matter which method is used: 3D printing affords the designer an architectural advantage with-limited bespoke manufacturing
But it’s expensive...
Powder printing is an option with machines similar to those at the GSD; only a slightmodificationisrequired.However, it is not currently a viable manufacturing process for architectural components. Material costs are high and from what I understand, due to its low density, powder-printed components are not capable of carrying the structural loads expected in architectural design.Market dynamics might change cost and access to these materials.
POWDER BED PRINTER
ABS EXTRUSION PRINTER+34 hr print timesubsidized at $155 USD
high resolutiontensile strength
+3.5 hr print timesubsidized at $160 USD low-density
subsidized at $900 USD low-density
Manufacturing Innovation
--Structural Loads Cont.--Ibelievethatthefieldof3Dprinted ceramics can contribute more to architectural design than the examples I’ve encountered to date..
Powder printing has it’s structural limits and the printing machines keep getting bigger and bigger. Extruding custom building components seems to have a greater range of promise.
I believe that multi-axis printing further increases this range of potentially printed architectural components.
I will explain 3,5 and 6-Axis printing in a minute.
LAUFEN ceramic factory
5-Axis Clay Extruder
TECHNOLOGICAL VALUE
3D Printed “Sand” Masonry, V. San Frantello & R. Rael
Flaherty, Joseph. “Architects Create a 3-D Printed Column That Survives Earthquakes.” Wired.com. Accessed June 7, 2015. http://www.wired.com/2014/10/architects-create-3-d- printed-column-survives-earthquakes/.
“LAUFEN Factory Visit: Ceramic Casting.” Designboom Architecture Design Magazine. 2012. Accessed January 18, 2016. http://www. designboom.com/design/laufen-factory-visit-ceramic-casting/.
Diagram by Author
Construction Technology-design driver
TEM factory, Montevideo. Uruguay by Eladio Dieste, 1960-2 Anderson, Eladio Dieste, p 77
Eladio Dieste
Block Research GroupSalginatobel Bridge
FORM WORK
Breitfuss, Klemen. “Free-form Catalan Thin-tile Vault, Zurich, Switzerland.” BLOCK Research Group. Accessed January 26, 2016. http://www.block.arch.ethz.ch/brg/project/free- form-catalan-thin-tile-vault.
Breitfuss, Klemen. “Free-form Catalan Thin-tile Vault, Zurich, Switzerland.” BLOCK Research Group. Accessed January 26, 2016. http://www.block.arch.ethz.ch/brg/project/free- form-catalan-thin-tile-vault.
Maillart, Robert. Engadine: Salginatobel Bridge General View, 1930, Data From: University of California, San Diego.
Lewis, Miles. “later brick & terra cotta.” History of Building class lecture, University of Melbourne.
“Some Images of the Salginatobel Bridge.” TWiki. Accessed January 26, 2016. http://twiki.org/cgi-bin/view/Salgina/ ImagesOfTheSalginatobelBridge.
Anderson, Stanford. Eladio Dieste Innovation in Structural Art. New York: Princeton Architectural Press, 2004.
As a personal interest, I used this opportunity to consider structural innovation with a contribution to construction technology.
I recognized that an arch is stable only when entirely complete but the form work used to construct the arch must be stable during the entire construction project; then carry the weight of the arch before it is removed. -As much design goes into the construction of the formwork asdoesthefinishedproject.I wanted a masonry building design that could be constructed using minimal formwork.
Even advanced digitally designed projects, such as those by the Block Research group, require innovative form work.-here, the Block Research group at the ETH-Zurich built the formwork on paper tubes in little trays that could soak in water to facilitate removal.
To investigate my hypothesze, this thesis project contributes to industrial ceramic manufacturing, digital design and fabrication processes inthefieldofarchitecture,and offers novel ideas to advance methods for building assemblies.
5 PAGE SPREADStructural Abstract
Outline of the design proposal as developed from a structural ideal.
STRUCTURAL ABSTRACT
Construction Concept
Many of us know about the Guastavino family’s work at the turn of the century where they developed and patented theconstructionof“fire-proof” masonry vaults. The catalan vault contributed to the development of my proposal, where I conceptualized a definedarchandinfillstructureto compose a series of masonry domes.
CONSTRUCTION TECHNOLOGY
Inset
Inset
Compression Ring Tension Line
AssemblySequence
Diagram by AuthorOchsendorf, John. “Guastavino Masonry Shells.” STRUCTURE Magazine. Accessed January 26, 2016. http://www. structuremag.org/?p=2046.
Geometric Concept
Knowing that I was looking for a novel, only-3D printable geometry, my design was focused on how to built a simple arch with little or no formwork.
The Block Research Group’s work illustrated that catalan vaulting can be used as an infillstrategytodistributethebuilding’s structural loads.
However. I was reluctant to grab onto the form-active structure in part knowing that I could not offer an accurate computational solution, making melessconfidentabouttheoverall design.
In any case, I feel that this is could be another research strategy, to custom print rib componentsandinfillwithGuastavino-type tiles.
Zurich, Switzerland, 2012 Melbourne, Australia, 2013
MASONRY FORM WORK
Diagram (above) by Author
Images (below): Breitfuss, Klemen. “Free-form Catalan Thin-tile Vault, Zurich, Switzerland.” BLOCK Research Group. Accessed January 26, 2016. http://www.block.arch.ethz.ch/brg/project/free- form-catalan-thin-tile-vault.
System Premise
Instead, I investigated an idea about a post-tensioned compression structure where a series of cables pull between blocks across the spine of the arch.
Essentially,thefirsttwoblocksare tied directly to a concrete foundation with every 4th block above strung together.
The assembly of the keystone blocks must be well planned and in any case, 4 different blocks can be used to construct this Roman arch of 18 voussoir elements.
POST TENSION CONSTRUCTION
Alternate Connetion
Corresponding View
Elevation
Tension Tie
Thrust Line
Section Concept
Center Point
Corresponding View
REV. DESCRIPTION
NO SCALE
SYSTEM PROPOSAL11.21.2015
tel: 606.271.7330
NOTE
Drawn By: Kevin Hinz; <[email protected]>;
DESCRIPTION:
MATERIAL:
HARVARD GRADUATE SCHOOL OF DESIGN
COMPONENT:
SCALE:
DATE- STRUCTURAL CONCEPTSYSTEM DIAGRAM
HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
...
Alternate Connetion
System Development
The construction sequence wouldbenfitfromaslottedchannel (opposed to a hollow chase originally concieved) to run the post-tensioned cable.The cables could be pre-cut, having rigid and threaded ends, bolted into place (shown in later drawing).
The system, modeled as a square to conceptualize, can be further developed within a designboundarydefinedbythe loads the arch is intended to carry.
BLOCK DEVELOPMENT
Tie
A1
Tie
A2
Tie
B1
Tie
B0
Tie
B2
Tie
A0
blk-A2j
Section: blk-B1j
Elevation
Section: blk-A1i
blk-A1i
foundation
blk-A1i
blk-B1iblk-B2j
Block Type
blk-A0i
foundation
blk-B2i
blk-B1jblk-B0i
blk-A1j
blk-A2i
blk-B1j
Speculative Design Boundary
12.01.2015
NO SCALE
CONCEPT BLOCKHARVARD GRADUATE SCHOOL OF DESIGN
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
DESCRIPTIONREV.-
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION: NOTE
ARCH COMPONENTHARVARD GRADUATE SCHOOL OF DESIGN
...AXONOMETRIC DIAGRAM
MISC CLAY BODY
Component Design
Because the production of geometry is cheap, a sadle, osteomorphic joint can be used to nest the blocks together, adding to the arch’s overall stability.
The articulated joint moves the center of gravity of each block, slightly effecting the point of buckling between blocks (diagram not shown).
Thebenefitsof3Dprintingcontribute to complex, well articulated mating surfaces.
Additional diesign features to incorporate could include:-the post-tension slot already described-water shedding geometry-connection strategies-motar channels + locks-channeltoacceptanddefinethe arch of a hand-laid Catalan vault
OSTEOMORPHIC NESTING
Block Connection
Center Point
-DATE COMPONENT:
MATERIAL:
REV. DESCRIPTION: NOTE12.01.2015
NO SCALE
CONCEPT BLOCKHARVARD GRADUATE SCHOOL OF DESIGN
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
DESCRIPTION
SCALE:
...AXONOMETRIC DIAGRAM
MISC CLAY BODY
OSTEOMORPHIC JOINTHARVARD GRADUATE SCHOOL OF DESIGN
4 PAGE SPREADStructural Proposal
Summary of structural behavior for design proposal
STRUCTURAL PROPOSAL
Geometric Concept
Each dome is organized by a planer circle at the foundation.Each rib is an arc, rotating along the base at about 1.7m intervals.
Although it will be a challenge toprintandfire(butpossible),Iestimate that the ceramic blocks would need to be about 0.5m square to support a structure this size.
Calculations would have to be madebyaqualifiedengineertoconfirmthehypothesis
~1.7m
1m
~1.7m
8.25
m
Alternate Connetion
Inset
Rotation free and translation free
Mortar
Tension Tie
1.0 Block
Alternate Connetion
K value
Center Point
Scale 1:100
Inset
Scale 1:10
0.7 2.0
Alternate ConnetionExposed Cavity
R12.8313m
Rotation free, translation fixed
Mortar Joint
Ground Tie
Scale 1:50
Rotation fixed, translation free
Rotation and translation fixed
0.5
Dome Organization
Tension Cable
Connection
Tension Tie
1.0 2.0
Moment Connection (assumed)
Arch Center-Line
Saddle Joint
Alternate Connetion
TECHTONICS
COMPONENT:
SCALE:Drawn By: Kevin Hinz; <[email protected]>;
DATECONCEPT PLAN
HARVARD GRADUATE SCHOOL OF DESIGN
REV.-
NOTEDESCRIPTION DESCRIPTION:
tel: 606.271.7330
MATERIAL:
01.01.2016
1:200
PLAN DIAGRAM PLANMISC CLAY BODY
...
HARVARD GRADUATE SCHOOL OF DESIGN
Structural Concept
Post-tensioned cables run up the spine as proposed earlier.
Cables are stagered and alternate between the joints of every fourth block.
Once constructed, the cables are encapsulated with motar for protection, creating a composite with the adjacent voussoir.
~1.7m
1m
~1.7m
8.25
m
Alternate Connetion
Inset
Rotation free and translation free
Mortar
Tension Tie
1.0 Block
Alternate Connetion
K value
Center Point
Scale 1:100
Inset
Scale 1:10
0.7 2.0
Alternate ConnetionExposed Cavity
R12.8313m
Rotation free, translation fixed
Mortar Joint
Ground Tie
Scale 1:50
Rotation fixed, translation free
Rotation and translation fixed
0.5
Dome Organization
Tension Cable
Connection
Tension Tie
1.0 2.0
Moment Connection (assumed)
Arch Center-Line
Saddle Joint
Alternate Connetion
~1.7m
1m
~1.7m
8.25
m
Alternate Connetion
Inset
Rotation free and translation free
Mortar
Tension Tie
1.0 Block
Alternate Connetion
K value
Center Point
Scale 1:100
Inset
Scale 1:10
0.7 2.0
Alternate ConnetionExposed Cavity
R12.8313m
Rotation free, translation fixed
Mortar Joint
Ground Tie
Scale 1:50
Rotation fixed, translation free
Rotation and translation fixed
0.5
Dome Organization
Tension Cable
Connection
Tension Tie
1.0 2.0
Moment Connection (assumed)
Arch Center-Line
Saddle Joint
Alternate Connetion
CONNECTIONS + POST TENSIONING
Alternate Connetion
Corresponding View
Elevation
Tension Tie
Thrust Line
Section Concept
Center Point
Corresponding View
REV. DESCRIPTION
NO SCALE
SYSTEM PROPOSAL11.21.2015
tel: 606.271.7330
NOTE
Drawn By: Kevin Hinz; <[email protected]>;
DESCRIPTION:
MATERIAL:
HARVARD GRADUATE SCHOOL OF DESIGN
COMPONENT:
SCALE:
DATE- STRUCTURAL CONCEPTSYSTEM DIAGRAM
HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
...
Alternate Connetion
Structural Concept
Smaller hyperbolic vaults, hopefully printed (we’ll have to see how large a component we can print) spring between single ribs.
The section of each vault is doubly curved and self-stable. This curvature, especially if glazed, should contibute to a softened light rolling over the surface edge.
Construction is alternated block, vault, block, etc.
The vaults function to help resist buckling, each engaging two layers of block at each row.
Inset
Inset
Compression Ring Tension Line
AssemblySequence
ASSEMBLY
Tension LineCompression Ring
Structural Concept
Vaults and ribs engage each other directly, continuously transfering and distributing loads around each horizontal ring; collapse of the rings inward would be countered by the post-tensioned cables traveling the spine of each rib.
Tension LineCompression Ring
LOAD DISTRIBUTION
6 PAGE SPREADProduction Design
Description of the tools and credits to the contributors which formed the base of printer construction.
PRODUCTION DESIGN
Extruder Summary
This chapter outlines a series of existing protoypical machinesIreconfiguredtofabricate the proposed block geometry.
IbeganbyreconfiguringtheMaP+S Research group’s existing piston extruder configuredtomountontheGSD’s ABB-4400-L30.
It’ssizecontributestodefinedproduction limits and detailed articulation, effecting design possibilites.
A single layer of coil is deposited along one continuous path that overshoots the edges of the panel. This is done to reduce time spent stopping and cutting coils, while also allowing the clay coils to catch the edges of the mold so that they don’t slide or shift. All excess clay cut off of the edges at the end is able to be reused.
Throughout the prototyping process, various milled foam molds were used as a means of testing various surface types. A key observation made through the proto-typing process was that a large degree of variation is possible within a single mold (Fig. 4). Based upon the deposition pattern and the density of the coils, one can achieve a wide range of opacities and visual effects (Fig. 5 and 6).
Fig. 4. Two handmade prototypes done on the same base mold
Fig. 5. Varying opacities over a single mold
Fig. 6. Robotically printed panels prior to firing
*Great experimental system-test platform for manufacturing -earlier Cevissima project -experimenting design potential -student work
--Scale of Extrusion Defined Limits--Safety Considerations
-Safety Improvements-Piston Design-Minimize Mechanical Errors-Minimize Student Abuse-Commercially Available Components-Reconfigurable Tips-Return to Original Configuration
M. Bechthold, C. Reinhart, et. al.
Stainless Steel Drive Screw
Portable Carriage Configuration
Re-designed Tension Rods
Improved Piston and Hydraulic Seal
Adaptable Nose Configuration
Existing Carriage and Drive Motor
Re-designed Compression Cone
Clear Extrusion Barrel
Simplified Motor Controls
MAP+S EXTRUDER
J. Friedman, H. Kim, O. Mesa.
Images lower right:Freidman, Jared, Heamin Kim, and Olga Mesa. “Experiments in Additive Clay Deposition: Woven Clay.” Rob|Arch 2014, May 17, 2014.
“Ceramic Printing.” YouTube. June 29, 2011. Accessed July 5, 2015. https://www.youtube.com/ watch?v=alyxH5QwAME. Harvard Graduate School of Design, Design Robotics Group.
Diagram (center) by Author
Extruder Summary
Modificationsinvolvedarobustcompression funnel and integrated feed tube.
Othersafetymodificationswere introduced or redesigned as necessary.
The re-design incorporated off-the-shelf hydraulic piston parts and a precise but adaptable nozzle tip.
*precise fit and seal parameters-smooth cone transition -adaptable attachment configuration
*nylon slip-fit sleeve (should be Acetal)-integrated nose pull - release-3D printable configuration-standard pipe-fitting attachment
-stainless steel drive screw-machined piston-commercial hydraulic piston cup*corrosion resistant / washable parts
0.6873,1.1904 (x,y) -0.6873,1.1904 (x,y)
-0.6873,-1.1904 (x,y)
-1.3745, 0.0 (x,y) 1.3745, 0.0 (x,y)
-0.6873,-1.1904 (x,y)
1.375"
3.000"
2.800"
4.500"
5.00
0"
2.62
5"
6.000"
2.250"
1.31
3"
1.375"
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3)
0.3215", 0.325" DEPTH for STEEL INSERTTYP (3)
Ø0.313" THRU [SEE SECTION A/B]TYP (4)
Ø0.500" 0.325" DEPTH [SEE SECTION A/B]TYP (4)
VIEW
4 - 20 SCREW
EXTRUDER NOSE CONEFACEMATERIAL:
NOTES:DRAWN AS BUILT WITH COORDINATESFOR THRU HOLE LOCATIONS
05.18.2015-1
DESCRIPTION:
HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
06.02.2015
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
Drawn By: Kevin Hinz; <[email protected]>; 1:1tel: 606.271.7330
DESCRIPTIONREV.-
DATE
SCALE:
COMPONENT:
6" ALUMINUM ROUND
NOSE - 01-1Original Machining DrawingDrawing as Fabricated
HARVARD GRADUATE SCHOOL OF DESIGN
1 COUNT - Beginning 6" Round
Ø0.600" 3" DEPTH [SEE SECTION A/B]TYP (4)
2.605"
2.605"
Ø6.000"
Ø1.500"
Ø3.500"
Ø6.000" Ø4.000" SEE MID SECTION
Ø0.313"THRU [SEE SECTION A/B]TYP (4)
6.000"VIEW
ECTION
MATERIAL:
DATEEXTRUDER NOSE CONETAIL
DESCRIPTION: COMPONENT:
SCALE:
PART COUNT
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
NOTES:
-106.02.2015HARVARD GRADUATE SCHOOL OF DESIGN05.18.2015
1:1
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] DESCRIPTIONREV.- Original Machining Drawing
Drawing as Fabricated1 COUNT - Beginning 6" Round
HARVARD GRADUATE SCHOOL OF DESIGN
NOSE - 026" ALUMINUM ROUND
2.62
5"
5.00
0" 1.25
0"
1.250"
Ø0.313"THRU [SEE SECTION DETAIL]TYP (4)
1.31
3"
4.500"
4.500"
Ø0.500" 0.325" DEPTH [SEE SECTION DETAIL]TYP (4)
0.3215", 0.325" DEPTH for STEEL INSERTTYP (3)
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3)
Ø6.000" Ø4.000" SEE NOSE 01
Ø0.600" 3" DEPTH [SEE DETAIL]TYP (4)
Ø0.313"THRU [SEE DETAIL]TYP (4)
2.605"
2.605"
Ø6.000"
Ø1.500"Ø3.500"
5.00
0"
0.31
3"0.325"
4.000"
0.675" 3.000"
0.50
0"
2.62
5"
6.00
0"1.31
3"1.
313"
0.60
0"
SECTION B
SECTION B
SECTION B
1.00
0"0.
675"
3.00
0"
4.00
0"
0.50
0"
0.32
5"
2.250"2.250"
SECTION A
PART COUNTREV.
1:2
EXTRUDER NOSE CONESECTIONS
COMPONENT:DATE
SCALE:DRAWN BY:
DESCRIPTION DESCRIPTION:
KEVIN HINZ
tel: 606.271.733005.18.2015
Kevin Hinz; <[email protected]>;-
MATERIAL:
SECTION A & B 1
6" ALUMINUM ROUND
Original Machining Drawing
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] HARVARD GRADUATE SCHOOL OF DESIGN
0.37
3"
1.188"
0.500" 0.756"
3.54
3"
0.188"
0.74
5"
0.37
3"
0.37
0"
0.74
5"
1.54
0"
0.625"
3.08
0"
1.000"
0.506"
0.76
0"
3.08
0"
0.506"
0.250"
0.250"
0.431"
1.047" APRX
0.400"
3.42
0"
THRU HOLE FOR 1/4" PINSNUG FIT
EXISTING ACME SCREW
SOCKET FOR 3/4 ACME SCREW
BEGINNING 3.5" ALUMINUM ROUND
TAP FOR 5/16-18
5/16-18 x 3/8" HEX SCREW
1/4" x 1.6" PIN, STEEL
1.5" FENDER WASHER THRU HOLE FOR 1/4" PINTIGHT FITEXISTING PLUNGER CUP
DESCRIPTION--1
06.02.201506.04.2015
EXTRUDER CYLINDER PLUNGER
SCALE:
DATE DESCRIPTION:
NOTES:ACME SCREW TO BE PINNED TO PLUNGERPLUNGER CUP TO BE SCREWED TO PUNGER
MATERIAL: 1:1
COMPONENT:REV.
tel: 606.271.7330Drawn By: Kevin Hinz; <[email protected]>;
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
HARVARD GRADUATE SCHOOL OF DESIGN
Original Machining Drawing5 SEPARATE PARTS:2 PARTS TO FABRICATE3 PARTS EXISTING
3.5" ALUMINUM ROUND
PLUNGER - 01REVISED Machining Drawing
0.37
3"
1.188"
0.500" 0.756"
3.54
3"
0.188"
0.74
5"
0.37
3"
0.37
0"
0.74
5"
1.54
0"
0.625"
3.08
0"
1.000"
0.506"
0.76
0"
3.08
0"
0.506"
0.250"
0.250"
0.431"
1.047" APRX
0.400"
3.42
0"
THRU HOLE FOR 1/4" PINSNUG FIT
EXISTING ACME SCREW
SOCKET FOR 3/4 ACME SCREW
BEGINNING 3.5" ALUMINUM ROUND
TAP FOR 5/16-18
5/16-18 x 3/8" HEX SCREW
1/4" x 1.6" PIN, STEEL
1.5" FENDER WASHER THRU HOLE FOR 1/4" PINTIGHT FITEXISTING PLUNGER CUP
DESCRIPTION--1
06.02.201506.04.2015
EXTRUDER CYLINDER PLUNGER
SCALE:
DATE DESCRIPTION:
NOTES:ACME SCREW TO BE PINNED TO PLUNGERPLUNGER CUP TO BE SCREWED TO PUNGER
MATERIAL: 1:1
COMPONENT:REV.
tel: 606.271.7330Drawn By: Kevin Hinz; <[email protected]>;
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
HARVARD GRADUATE SCHOOL OF DESIGN
Original Machining Drawing5 SEPARATE PARTS:2 PARTS TO FABRICATE3 PARTS EXISTING
3.5" ALUMINUM ROUND
PLUNGER - 01REVISED Machining Drawing
3.983"
3.81
9"
1.122"
2.243"
1.991"
2.730"
0.875"
1.00
0"
2.828"
6.000" initial diameter
1.750"
1.750"
1.750"
0.75
9"
3.505"
0.32
5"
66.00°
24.00°
24.00°
5.656"
1.08
9"1.
971"
0.750"
0.3215", 0.325" DEPTH for 3/8" STEEL INSERTTYP (3) SEE NOSE-02 FOR DETAIL
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3) SEE NOSE-02 FOR DETAIL
SECTION LINE
SECTION LINE
or 1/4 - 20 SCREW02 FOR DETAIL
COMPONENT:DATE
NOTES:
MATERIAL:
PART COUNT
SCALE:
EXTRUDER NOSE CONEMID-SECTION
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
DESCRIPTION:
-106.02.2015HARVARD GRADUATE SCHOOL OF DESIGN05.18.2015
1:1
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] DESCRIPTIONREV.- Original Machining Drawing
Drawing as Fabricated
HARVARD GRADUATE SCHOOL OF DESIGN
MID SECTION6" ALUMINUM ROUND
1 COUNT - Beginning 6" Round
3.983"
3.81
9"
1.122"
2.243"
1.991"
2.730"
0.875"
1.00
0"
2.828"
6.000" initial diameter
1.750"
1.750"
1.750"
0.75
9"
3.505"
0.32
5"
66.00°
24.00°
24.00°
5.656"
1.08
9"1.
971"
0.750"
0.3215", 0.325" DEPTH for 3/8" STEEL INSERTTYP (3) SEE NOSE-02 FOR DETAIL
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3) SEE NOSE-02 FOR DETAIL
SECTION LINE
SECTION LINE
or 1/4 - 20 SCREW02 FOR DETAIL
COMPONENT:DATE
NOTES:
MATERIAL:
PART COUNT
SCALE:
EXTRUDER NOSE CONEMID-SECTION
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
DESCRIPTION:
-106.02.2015HARVARD GRADUATE SCHOOL OF DESIGN05.18.2015
1:1
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] DESCRIPTIONREV.- Original Machining Drawing
Drawing as Fabricated
HARVARD GRADUATE SCHOOL OF DESIGN
MID SECTION6" ALUMINUM ROUND
1 COUNT - Beginning 6" Round
1.688"
1.10
0"
1.122" 0.997"
3.375"
1.993" ID
1.375"
2.243" OD
1.374"
1.993"1.750"
0.94
8"
66.00°
24.00°
0.875"
0.997"
1.506"0.906"
0.300"
0.753"
0.25
0"
0.54
6"1.
152"
1.94
8"
0.378" 0.378"
BEGINNING 3.5" ALUMINUM ROUND
SYNTHETIC INSERT
.9060" DIA, TAP 3/4 NPT
0.2010" DIA, TAP 1/4 - 20 SCREW
TYP (3)
0.1250" THICK
0.2660" DIA, THRU 1/4 - 20 SCREWTYP (3)
MATERIAL: 2.25" OD SYNTHETIC TUBE,
NOTES:SYNTHETIC INSERT TO FIT IN NOSE CONESEE DRAWINGS: NOSE 01 & NOSE 01-1
PART COUNT06.02.2015
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] REV.
Drawn By: Kevin Hinz; <[email protected]>;
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330
-DATE
SCALE:
COMPONENT:DESCRIPTION:EXTRUDER NOSE CONEFACE
1:1
DESCRIPTIONOriginal Machining Drawing
HARVARD GRADUATE SCHOOL OF DESIGN
2 SEPARATE PARTS / 2 SEPARATE MATERIALS
3.5" ALUMINUM ROUND
NOSE TIP - 01
1.688"
1.10
0"
1.122" 0.997"
3.375"
1.993" ID
1.375"
2.243" OD
1.374"
1.993"1.750"
0.94
8"
66.00°
24.00°
0.875"
0.997"
1.506"0.906"
0.300"
0.753"
0.25
0"
0.54
6"1.
152"
1.94
8"
0.378" 0.378"
BEGINNING 3.5" ALUMINUM ROUND
SYNTHETIC INSERT
.9060" DIA, TAP 3/4 NPT
0.2010" DIA, TAP 1/4 - 20 SCREW
TYP (3)
0.1250" THICK
0.2660" DIA, THRU 1/4 - 20 SCREWTYP (3)
MATERIAL: 2.25" OD SYNTHETIC TUBE,
NOTES:SYNTHETIC INSERT TO FIT IN NOSE CONESEE DRAWINGS: NOSE 01 & NOSE 01-1
PART COUNT06.02.2015
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] REV.
Drawn By: Kevin Hinz; <[email protected]>;
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330
-DATE
SCALE:
COMPONENT:DESCRIPTION:EXTRUDER NOSE CONEFACE
1:1
DESCRIPTIONOriginal Machining Drawing
HARVARD GRADUATE SCHOOL OF DESIGN
2 SEPARATE PARTS / 2 SEPARATE MATERIALS
3.5" ALUMINUM ROUND
NOSE TIP - 01
DESIGN FEATURES
Diagram (all) by Author, sponsored by MaP+S
It was important for me to integrateexisting,readytofindproducts in the initial stages of the experiments.
With help from Jessica Brandl and Brian Czibesz, I learned techniques to hydrate the clay and load the piston. Essentially, a 25lb bag of clay is perforated and soaked in water for 12 hrs. With this level of perforation, the clay absorbed exactly 2lbs of water.
The result is a plug-and-play system extruding approximately 14lb of hydrated Standard Clay C/04 Red Earthenware before a recharge is nessacary.
The piston extruder, designed in this case for clay, is actually a multi-material extruder, expanding the possibilities of this research.
Extruder Summary
LOADHYDRATE PRINT
Images by author
Printer Summary
The project continued with the deployment of an opensource CNCconfigurationtotestthematerial parameters.
My early research, sponsored by Prof Bechthold, was supplemented by technical knowledge from Daekwon Park, GSD DDes and ceramic artists Jessica Brandl and Brian Czibesz whom I met at the Harvard Ceramics Lab in Allston.They are an endless source of knowledge to begin the process of understanding the clay’s material properties.
Other contributions involved the WASP Project’s open source extruder stylus, a component I reverse engineered and fabricated with help from Harvard fabrication facilities.
Mobile Printer ConfigurationMaP+S sponsorshipDaekwon Park contribution--Jessica Brandl and Brian CzibeszOpen Source Delta Configuration--online files & plug + play componentsAffordable test bedHighly mobile machineAssistance from Harvard Ceramics -Kathy King
Marlin Firmware -delta printerJohnathan Keep -ceramic printing + delta summarySlic3r -g-code generatorWASP -(almost) open source auger extruder
Commercially available screw auger. €650. WASP, Massa Lombarda, Italy.WASP (World’s Advanced Saving Project) is using the development and sale of Delta-Style 3D printers and printer components to fund a socially conscience agenda for affordable housing. Current research includes a 12m tall Delta-style printer and 3D printed concrete beam components. The WASP housing is now open-source, not including the critical transmission component.
http://www.wasproject.it/w/en/
OPEN SOURCE + COMMERCIAL COMPONENTS
Image (left) by Author Images top:“Clay Extruder Kit 2.0.” WASP. Accessed September 10, 2015. http:// www.wasproject.it/w/en/.
Image low right, by Author.
Printer Summary
The extruder stylus uses an off-the-shelf stepper or DC motor to accurately control the feedrate of the clay body “piped-in” from the piston extruder.
More affectionatly named the Gimlet, a small T-shaped cork screw tool for boring holes, the extruderbodyisconfiguredto be mounted on either the 3-Axis Delta-style printer or to a standard ATI-QC-11 Interface puck for the ABB robotic arm.
3D Printed Housing, ABS
Machined Nylon (Acetal Preferred)
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
Aluminum or Stainless Backing Plate
1ct.- 42mm NEMA17 Stepper Motor
1ct.- Aluminum Flex Shaft Coupler5mm - 5mm
1ct.- 19mmOD x 6mmID x 6mm Bearingor other according to Auger Dimensions
1ct- 50ml or 60ml Syringew/ Luer-Lok Tip
Auger: 1/4" Lag Screw3.5" Length, 2.5" Tooth
12mm Push-To-Connect Air Fitting
Machined Nylon (Acetal Preferred)
3D Printed Housing, ABS
Stainless or AluminumMounting Bracket [Fan]
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
NOTE: ID is about 0.1mm greater than auger DIA
1ct- 2 mm x 18ID O-Ring
Barrel [ideally grooved]
Auger[smooth]
AUGER EXTRUDER
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AUGER DIAGRAM...
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1ct.- Aluminum Flex Shaft Coupler5mm - 5mm
30cc Syringe w/ Luer-Lock Tip
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
1ct.- 19mmOD x 6mmID x 6mm Bearing
2ct.- 18-8 Stainless Steel Threaded Stand-Off 4-40 3/16" Hex, 3/4" Length
3D Printed Housing, ABS
1ct- 2 or 3mm x 18ID O-Ring
Auger: 1/4" Lag Screw3.5" Length, 2.5" Tooth
Stainless or AluminumMounting Bracket [Fan]
12mm Push-To-Connect Gas Fitting
Aluminum or Stainless Backing Plate
Machined Nylon (Acetal Preferred)
1ct.- 42mm NEMA17 Stepper Motor
HARVARD GRADUATE SCHOOL OF DESIGN
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AUGER EXTRUDERMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
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... AUGER DIAGRAMAXONOMETRIC DIAGRAM
HARVARD GRADUATE SCHOOL OF DESIGN MULTI
AUGER EXTRUDER / PRINT STYLUS
Images by Author, sponsored in part by MaP+S
6 PAGE SPREADMulti-Axis Extrusion
Analysis of precedents and discourse outlining parameters around multi-axis printing strategies.
MULTI-AXIS EXTRUSION
3D Extrusion
I discovered that the components composing my prototypical architecture are complex enough that it would bedifficulttoproducewithexisting 3-Axis extrusion technologies. One of the sample blocks I printed illustratedthatdifficulty.
A quick examination of extrusion precedents shows this: the surface of Prof. Bechthold’s 4-Axis extrusion (from what I observe) is much more articulated and precise curvature than achievable by a 2D layered extrusion.
Fordefinitionandclarification:--WASP (World’s Advanced Saving Project)*open source foundation, now focused on large size (12m printer), now moving to 3D printed concrete.
I combined these two projects to develop my conclusions for this thesis.
Bechthold et al, Cambridge, 2011 WASP, Italy, 2014
CLAY EXTRUSION PRECEDENTS
“Novità da WASP - Stampanti 3D.” WASP. Accessed August 16, 2015. http://www.wasproject.it/w/argilla-2/.
“Ceramic Printing.” YouTube. June 29, 2011. Accessed July 5, 2015. https://www.youtube.com/ watch?v=alyxH5QwAME. Harvard Graduate School of Design, Design Robotics Group.
Extrusion Precedents
Most of the extruded ceramic printing I encountered deployed 6-Axis robotic arms to print in 3-Axis.
The IAAC in Barcelona has developed these processes further than anyone. Their current research is integrating speed and column-like components to develop novel structural geometries not unlike what we see hear.
The most interesting project I uncovered was in Buckinghamshire, UK where they used a Kuka and a sausage extruder to print columnare structures.
These examples prove that there are many innovations possible and many directions to turn for research.
Friedman et al, Cambridge, 2014
THREE AXIS PRINTING
Barcelona, 2015Barcelona, 2013
Buckinghamshire, UK, 2014
Wainwright, Oliver. “Clay Robotics: The Future of Architecture Is Happening Now in a Chilterns Farm.” The Gaurdian. August 8, 2014. Accessed December 1, 2015. http://www.theguardian.com/artanddesign/architecture- design-blog/2014/aug/08/clay-robotics-architecture-chilterns-farm.
“PYLOS PROJECT’S SUSTAINABLE HOUSE 3D PRINTING GROWS TALLER - Microfabricator.com.” Microfabricator.com. Accessed December 1, 2015. http:// microfabricator.com/articles/view/ id/561d3ab43139447d238b4567/pylos- project-s-sustainable-house-3d-printing-grows-taller.
Naramore, Cameron. “Towards Automated Clay Home Construction, with FabClay.” 3D Printer. February 4, 2013. Accessed December 1, 2015. http:// www.3dprinter.net/automated-clay-home-construction-with-fabclay.
Multi-Axis Extrusion
Let me iterate the differences of multi-axis printing techniques and the strategize they support:
3-Axis is simple X,Y,Z movement of the print head.
5-Axis rotates the tip in a local X-Y coordinate system, in sync with XYZ table travel.
6-Axis printing is realizable only with an articulated print nozzle, where the orientation of ashapednozzleinfluencesthecross section of an extrusion coil.
I choose to stay with the cylindrical extrusion nozzle to limit complexity.
6-AXIS5-AXIS3-AXIS
THREE AXIS PRINTING
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“Ceramic” Tooling
Basic layering strategize wereidentifiedandproperlyarticulated to achieve satisfactory results.
All of these parameters, layer height, step over, overlay, coilsize,flowrate,canbepredicted and controled.
CERAMIC TOOLING
Layer Alignment
1.29 mm^20.85 mm stepover
Excessive Material
Low Flow
1.29 mm^2
Solid Configuration
Infill Configuration
1.29 mm^2
Controlled Deposition
Low-No Compression
1.29 mm^2
Under Compression
High Flow
Over Compression
Increased StepOver
1.29 mm^2
Collapsed Structure
Ideal Contact
Layer Compression
Gap
Surface Drop
Pulled Coil
Pushed Coil
SlumpGap
2-Perimeters for Example
Graduated Layer Building
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...AXONOMETRIC DIAGRAM TOOLPATH PARAMETERS II
MISC CLAY BODY
5-Axis Advantage
Oneofthemostsignificantcontributions to 5-Axis technology contributes to the resolutionofthefinalproduct,especially when producing complex geometric shapes.
Similar tooling parameters exist between 3 & 5-Axis printing (stepovers, layer height, overlap, etc).Themostinfluencialresultisthefinalplaneofsurfacecontact between the print nozzle and already laid extrusion coil.
full step-up(not possible)
1.29 mm^2
50% InFill
1.7mm x 0.85mm
5-Axis Solution50% InFill
50% step-up
1.29 mm^21.29 mm^2
5-Axis SolutionSolid InFill
1.29 mm^2
Step-Over x Step-Up: 1.7mm x 1.7mm2.27 mm^2 1.29 mm^2
Solid Configuration
1.7mm x 0.85mm 1.7mm x 0.85mm
1.7mm x 0.85mm
1.7mm x 0.85mm
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MISC CLAY BODY
MULTI AXIS ADVANTAGE
5-Axis Advantage
Themostsignificantcontribution could be the articulation of the tooled ceramic coil.
Flow-rate has the most perfound effect on coil compression but it can be messy and often uncontrolled.
5-Axisarticulationmodifiesthe way succesive coils are compressed together, having asignificanteffectonthearrangement of the ceramic medium’s micro-structure. I willbrieflyexplaintheplateletstructure in a moment.
5-Axis Step-Over
0.5*Bead Diameter = Nozzle Width
Bead Diameter = Nozzle Width
Interlocked Layers
Standard Flow Rate
Increased Flow Rate
3-Axis Step-Over
25% Overlay
Simple Compression Zone
Pulled Coil
Complex Compression Zone
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HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
AXONOMETRIC DIAGRAM 5-AXIS FLOW
MICRO-EFFECT
9 PAGE SPREADProcess Design
Flow and the material properties effecting tooling and the architectural result.
PROCESS DESIGN
Flow Technology
Clay bodies have a platelet micro structure. These platelets are naturally misaligned but organizewhenflowingduringthe extrusion process. They become even further aligned withextensiveflow.
This platelet structure has a greater capacity to resist compression when they are stackedflatagainsteachother.This should contribute to the structural capacity of bricks extruded in this manner.
**Material properties have a profound effect on architectural design.
DRAG, SHEAR AND STRUCTURE
Ejection Nozzle
Deposited Layers(modeled part)Control Surface
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...AXONOMETRIC DIAGRAM LAYER DEPOSITION
Flow Technology
Thematerialflowandtoolpathcoordination between the piston extruder and, in this case, the ABB robot, can be accurately calculated and controled.
Part of my work included thinking through a redesign of particular machine components, including a ready to install gear reduction decreasing the speed of the pistonextrudersignificantly(avoiding stalling). The higher degree of motor speed control at the piston will support a morestableflowrate.
The interface for the extruder to sync with the robot includes a plug-and-play Arduino motor controler reading a digital output signal from the ABB controller.
Piston Length: PL
Piston Area: PA
Piston Volume: PV
Piston Flow: PF
Piston Speed: PS
Tube Length: TL
Tube Area: TA
Tube Volume: TV
Tube Speed: TS
Tube Flow: TF
Auger Speed: GS
Auger Volume: GV
Auger Flow: GF
Pitch Volume: HV
Barrel Volume: BV
Shaft Volume: SV
Flight Volume: FV
Deposition Volume: -body of material to be deposited / second for given motor speed--Auger Pulse: required Auger revolutions / second
Deposition Flow = Tube Flow = Auger Flow = Piston Flow
DefinitionsAuger Shaft: center shaft supporting auger Auger Flight: screw coils around the auger shaftAuger Pitch: distance between two flights Extruder Column Length (EL): length of column around auger for pitchPitch Volume (HV): volume of clay body between two flights HV = EL - Shaft Volume - Flight VolumeDeposition Volume (DV): Pitch Volume * EL Deposition Flow (DF): Deposition Volume * Revolution / SecRev / Sec = DF / DV
Piston Volume: PV = PA * PL
Piston Flow: PF = PV * PS
Tube Volume: TV = TA * TL
Tube Flow: TF = TV * TS
TF = PF
PF = TV * TS
Tube Speed: TS = PF / TV
Pitch Volume (per pitch): HV = BV - SV - FV
Deposition Volume: DV = PV * EL
Deposition Flow: DF = DV * Rev / Sec Rev/Sec = DF / DV
SYSTEM FLOW
Max Stepper Speed: approximately 200rpm = 3.33 rps
EX: Take a Piston motor making 10 seconds per revolution with an acme screw moving 0.01”, equating to a flow rate of approximately 1577 mm^3 / second.Piston Flow must equal the Tube Flow, Auger Flow and hence Deposition Flow (independently), an Auger must spin approximately 21 revolutions / second to keep up with the large piston extruder.
Actual Rate Data To-Be-Collected
Deposition Volume: -body of material to be deposited / second for given motor speed
Deposition Flow = Tube Flow = Auger Flow = Piston Flow
DefinitionsAuger Shaft: center shaft supporting auger Auger Flight: screw coils around the auger shaftAuger Pitch: distance between two flights Extruder Column Length (EL): length of column around auger for pitchPitch Volume (HV): volume of clay body between two flights HV = EL - Shaft Volume - Flight VolumeDeposition Volume (DV): Pitch Volume * EL Deposition Flow (DF): Deposition Volume * Revolution / SecRev / Sec = DF / DV
Feed RateAuger RateTube RatePiston Rate
Specified Feedrates Delta: 80mm/s ABB: 78mm/s
Measured Feedrates Delta Feedrate: 14mm/s ABB Test: 46.65mm/s
Piston Length: PL Piston Area: PA Piston Volume: PV Piston Flow: PF Piston Speed: PS
Tube Length: TL Tube Area: TATube Volume: TV Tube Speed: TS Tube Flow: TF
Auger Speed: GSAuger Volume: GVAuger Flow: GFPitch Volume: HVBarrel Volume: BVShaft Volume: SVFlight Volume: FV
Piston Volume: PV = PA * PLPiston Flow: PF = PV * PS
Tube Volume: TV = TA * TLTube Flow: TF = TV * TS TF = PF PF = TV * TSTube Speed: TS = PF / TV
Pitch Volume (per pitch): HV = BV - SV - FVDeposition Volume: DV = PV * EL
Deposition Flow: DF = DV * Rev / Sec Rev/Sec = DF / DV
Rotation Rate
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FLOW CALCULATIONS
MISC CLAY BODY
Flow Technology
These parameters are very important to control because they, when combined with the toolpath and nozzle parameters outlined earlier, profoundly effect the resulting product.
Digital
Density
Resolution
Porosity
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HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
MACHINE EFFECT
Flow Technology
Flow rates, a relationship between auger speed and feed rate, are the greatest contributing factor to the resulting material surface, including this articulated (and calculatable) looping pattern.
MATERIAL AFFECT
Flow Technology
5-Axis tooling should allow a greator range of geometric opportunities, expanding the range of un-supported cantilevers in component design.
MACHINE ARTICULATION
40.00°
anticipated
60.00° MIN
Cantilever Potential25% OverlayLimited Cantilever Potential
5-Axis3-Axis
Unsupported OverhangUnsupported Overhang
Articulated Tooling
Integrated Structure
HARVARD GRADUATE SCHOOL OF DESIGN
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MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
5-AXIS CANTLEVER
Flow Technology
The development of a multi-axis extrusion is the major contributing body of work to this production technology. The way robots handle code effect their potential to be integrated into production, a point to pause and consider before proceeding.
As the test block was designed, the toolpath has over 65000 targets; processing this amount of information is difficultforthecontrolleronhand.
To test the proposed CNC design methods, I simulated just 700 targets, offering a more simple understanding of the processes employed.My initial assessment suggests that a 5 or 6-Axis gantry would provide a more easily programmable platform to continue this research direction.
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MACHINE ARTICULATION
Test Block
To test my observations, I developed a simple osteomorphic block that had the geometrical characteristics that would be encountered in the design proposal.
The following section drawings are shown here.
5-Axis Tooling
c-B
c-A
c-B
c-A
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MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
... PROTOTYPICAL BLOCK BLOCK IS A TEST SUBJECT APPROXIMATING LIKELY ENCOUNTERED GEOMETRIES
PROTOTYPICAL BLOCK
Tooling Strategy
The initial tooling strategy I composed involved a simple linear interpolation of the part’s cross section. The intersection of the tool path with the geometric surface was interpreted.
If the surface’s vertical section was convex (when viewing from the part center), the tool path would be orientated toward the surface normal.
If the surface’s vertical section was concave (when viewing from the part center), the tool path would be orientated toward the surface tangent.
The interstitial tool path would be an interpolation between the opposing orientations.
Target count, and computational weight, would be determined by the desired part resolution.
Section c-B5-Axis Tooling
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MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
... SECTION c-B EXPERIMENTAL SURFACE ARTICULATION
Section c-A5-Axis Tooling
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AXONOMETRIC DIAGRAM... SECTION c-A EXPERIMENTAL SURFACE ARTICULATION
TOOLING STRATEGY
Tooling Strategy
This strategy proved to create problems for ceramic extrusion at the test resolution (aprox. 1-5mm). Nevertheless, the investigation and subsequent discussion with contributors proved a valuable part of the research, highlighting future avenues of exploration.These ideas and concepts will be investigated in the coming months and released in a forthcoming publication.
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FUTURE ARTICULATION
4 PAGE SPREADDesign Proposal
These pages showcase a few possible scenarios for the design proposal; an illustration of what sort of architecture is possible using this type of technology.
Brandon Johnson is the major contributor for the rendering artistry shown in the following images.
DESIGN PROPOSAL
Design Proposal
Section view.
Brandon Johnson, architectural rendering artist.
Design Proposal
View 01.Brandon Johnson, architectural rendering artist.
Design Proposal
View 02.
Brandon Johnson, architectural rendering artist.
Design Proposal
Night view.
Brandon Johnson, architectural rendering artist.
6 PAGE SPREADRealization + Representation
These pages showcase a small portion of the items produced to realize this thesis, including the machines and ceramic bricks printed during the semester.In addition, a model was madetohighlightthefinaldesign proposal, also shown in photographs here.
MATERIALIZATION
Machines
Clockwise from left:
The Delta-Style 3D printer and piston extruder was sponsored by the Harvard Graduate School of Design MaP+S group.
Daekwon Park, GSD DDes, contributed logistic and technical support during the construction of the Delta printer. Buildfilesweremodifiedbytheauthor, originally constructed from technical information provided by Johnathan Keepand Brian Czibesz.
Staff in the GSD FabLab contributed to the reconfigurationofthepistonextruder.
The auger extruder shown herewasmodifiedbythteauthor from an open-source design released by WASP.
PrinterConfiguration
Clockwise from left:Auger extruder mounted above brick06. The surface is textured by modifying the ratio offlowandfeedrate,resultingin a predictable loop pattern for the deposited coil. The smaller ‘buttons’ are test prints looking at the articulation of the extruder’s print resolution.
The auger extruder above brick05, a sample geometry illustrating an easily achieved resolution and geometric detail.
The auger extruder shown with digital output control panel designed by the author. The devise regulates the speed of auger rotation while responding to a digital output signal sent from the ABB robotic arm controller.Nathan Melenbrink, GSD MDes, contributed to the Arduino setup and component design.
Text Prints
These 8 bricks were printed with using the above Delta printer.
Display Case + Concept Model
Clockwise from left:
Auger Extruder box by Michael J. Smith.
ABS print. Osteomorphic test bricks representing a geometric structure having the qualities of the proposed design.
ABS print, stainless steel and nylon hardware. Concept block showing a post-tensioned arch.
Design Proposal
ABS print, high density foam
1:100 model of the overall design proposal deploying this 3D ceramic printing technology.
Design Proposal
ABS print, high density foam
1:100 model of the overall design proposal deploying this 3D ceramic printing technology.
Sarah Norman, GSD DDes, model repair.
2 PAGE SPREADRepresentative Work
Two A-1 panels printed for the grading session forllowing the reviews.
GRADING SUBMISSION
Representative Work
A-1 boards printed and submitted for grading.
Alternate Connetion
Corresponding View
Elevation
Tension Tie
Thrust Line
Section Concept
Center Point
Corresponding View
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Alternate Connetion
Inset
Inset
Compression Ring Tension Line
AssemblySequence
~1.7m
1m
~1.7m
8.25
m
Alternate Connetion
Inset
Rotation free and translation free
Mortar
Tension Tie
1.0 Block
Alternate Connetion
K value
Center Point
Scale 1:100
Inset
Scale 1:10
0.7 2.0
Alternate ConnetionExposed Cavity
R12.8313m
Rotation free, translation fixed
Mortar Joint
Ground Tie
Scale 1:50
Rotation fixed, translation free
Rotation and translation fixed
0.5
Dome Organization
Tension Cable
Connection
Tension Tie
1.0 2.0
Moment Connection (assumed)
Arch Center-Line
Saddle Joint
Alternate Connetion
Tie
A1
Tie
A2
Tie
B1
Tie
B0
Tie
B2
Tie
A0
blk-A2j
Section: blk-B1j
Elevation
Section: blk-A1i
blk-A1i
foundation
blk-A1i
blk-B1iblk-B2j
Block Type
blk-A0i
foundation
blk-B2i
blk-B1jblk-B0i
blk-A1j
blk-A2i
blk-B1j
Speculative Design Boundary
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ARCH COMPONENTHARVARD GRADUATE SCHOOL OF DESIGN
...AXONOMETRIC DIAGRAM
MISC CLAY BODY
Max Stepper Speed: approximately 200rpm = 3.33 rps
EX: Take a Piston motor making 10 seconds per revolution with an acme screw moving 0.01”, equating to a flow rate of approximately 1577 mm^3 / second.Piston Flow must equal the Tube Flow, Auger Flow and hence Deposition Flow (independently), an Auger must spin approximately 21 revolutions / second to keep up with the large piston extruder.
Actual Rate Data To-Be-Collected
Deposition Volume: -body of material to be deposited / second for given motor speed
Deposition Flow = Tube Flow = Auger Flow = Piston Flow
DefinitionsAuger Shaft: center shaft supporting auger Auger Flight: screw coils around the auger shaftAuger Pitch: distance between two flights Extruder Column Length (EL): length of column around auger for pitchPitch Volume (HV): volume of clay body between two flights HV = EL - Shaft Volume - Flight VolumeDeposition Volume (DV): Pitch Volume * EL Deposition Flow (DF): Deposition Volume * Revolution / SecRev / Sec = DF / DV
Feed RateAuger RateTube RatePiston Rate
Specified Feedrates Delta: 80mm/s ABB: 78mm/s
Measured Feedrates Delta Feedrate: 14mm/s ABB Test: 46.65mm/s
Piston Length: PL Piston Area: PA Piston Volume: PV Piston Flow: PF Piston Speed: PS
Tube Length: TL Tube Area: TATube Volume: TV Tube Speed: TS Tube Flow: TF
Auger Speed: GSAuger Volume: GVAuger Flow: GFPitch Volume: HVBarrel Volume: BVShaft Volume: SVFlight Volume: FV
Piston Volume: PV = PA * PLPiston Flow: PF = PV * PS
Tube Volume: TV = TA * TLTube Flow: TF = TV * TS TF = PF PF = TV * TSTube Speed: TS = PF / TV
Pitch Volume (per pitch): HV = BV - SV - FVDeposition Volume: DV = PV * EL
Deposition Flow: DF = DV * Rev / Sec Rev/Sec = DF / DV
Rotation Rate
HARVARD GRADUATE SCHOOL OF DESIGN
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FLOW CALCULATIONS
MISC CLAY BODY
Kevin HinzLeire Asensio Villoria, Lecturer in Architecture
Brick Geometries: 5-Axis Additive Manufacturing for Architecture
Building Technologies profoundly affect architectural design. Digital Technologies offer compu-tational models to analyze structure, articulate design intention and develop creative production techniques. The means, methods and exchange of building construction knowledge is advancing on many fronts. However, traditional material systems still dominate the architectural pallet. Glass, steel, concrete, clay and wood are cut, shaped, bent and assembled in increasingly complex ways. It is the architect’s job to compose and orchestrate these systems. With this knowledge of production, materi-als and structure, the architect can integrate the skill and intelligence at the core of architecture.
Brick Geometries interrogates how digital technology can contribute to 6000 years of knowledge in architectural ceramics. Historically associated with craft-based manufacturing or high-volume industrial production, novel ceramic forms and innovative brick structures are typically developed from a ready-made, already existing selection of building components. This research proposes a new approach to the fabrication process of ceramic materials, constructing the tools and developing the material technology to explore 5-Axis Additive Manufacturing as a function to rethink construction methods and geometric form. The project exploits material effect of the clay body, design computa-tion and software manipulation to innovate on what is becoming a 21st century craft.
1ct.- Aluminum Flex Shaft Coupler5mm - 5mm
30cc Syringe w/ Luer-Lock Tip
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
1ct.- 19mmOD x 6mmID x 6mm Bearing
2ct.- 18-8 Stainless Steel Threaded Stand-Off 4-40 3/16" Hex, 3/4" Length
3D Printed Housing, ABS
1ct- 2 or 3mm x 18ID O-Ring
Auger: 1/4" Lag Screw3.5" Length, 2.5" Tooth
Stainless or AluminumMounting Bracket [Fan]
12mm Push-To-Connect Gas Fitting
Aluminum or Stainless Backing Plate
Machined Nylon (Acetal Preferred)
1ct.- 42mm NEMA17 Stepper Motor
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330 NONE
AUGER EXTRUDERMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
Drawn By: Kevin Hinz; <[email protected]>;
NOTES:
10.06.2015
MATERIAL:
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION PART COUNTDESCRIPTION:
... AUGER DIAGRAMAXONOMETRIC DIAGRAM
HARVARD GRADUATE SCHOOL OF DESIGN MULTI
3D Printed Housing, ABS
Machined Nylon (Acetal Preferred)
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
Aluminum or Stainless Backing Plate
1ct.- 42mm NEMA17 Stepper Motor
1ct.- Aluminum Flex Shaft Coupler5mm - 5mm
1ct.- 19mmOD x 6mmID x 6mm Bearingor other according to Auger Dimensions
1ct- 50ml or 60ml Syringew/ Luer-Lok Tip
Auger: 1/4" Lag Screw3.5" Length, 2.5" Tooth
12mm Push-To-Connect Air Fitting
Machined Nylon (Acetal Preferred)
3D Printed Housing, ABS
Stainless or AluminumMounting Bracket [Fan]
ATI QC-11 Interface Mount
ATI: QC-11 Tool Changer
NOTE: ID is about 0.1mm greater than auger DIA
1ct- 2 mm x 18ID O-Ring
Barrel [ideally grooved]
Auger[smooth]
AUGER EXTRUDER
SCALE: 2:1
SCALE: 1:1
DESCRIPTIONMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
SCALE: 1:1
HARVARD GRADUATE SCHOOL OF DESIGN10.06.2015
REV.-
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:
AS NOTED
PART COUNTAXONOMETRIC DIAGRAM
MULTI
AUGER DIAGRAM...
HARVARD GRADUATE SCHOOL OF DESIGN
1.375"
1.375"
1.37
5"
6.000"
2.62
5"
5.00
0"
4.500"
2.800"
3.000"
2.250"
1.375"
1.31
3"
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3)
0.3215", 0.325" DEPTH for STEEL INSERTTYP (3)
Ø0.500" 0.325" DEPTH [SEE SECTION A/B]TYP (4)
Ø0.313" THRU [SEE SECTION A/B]TYP (4)
VIEW
4 - 20 SCREW
HARVARD GRADUATE SCHOOL OF DESIGN
Drawn By: Kevin Hinz; <[email protected]>;
NOTES:AS BUILT
-1
DATEMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] COMPONENT:EXTRUDER NOSE CONEFACE
PART COUNT
SCALE: 1:1
05.18.2015 -
MATERIAL:
REV.
06.02.2015
DESCRIPTION DESCRIPTION:
tel: 606.271.7330
1 COUNT - Beginning 6" RoundOriginal Machining Drawing
6" ALUMINUM ROUNDHARVARD GRADUATE SCHOOL OF DESIGN
Drawing as Fabricated NOSE - 01
0.6873,1.1904 (x,y) -0.6873,1.1904 (x,y)
-0.6873,-1.1904 (x,y)
-1.3745, 0.0 (x,y) 1.3745, 0.0 (x,y)
-0.6873,-1.1904 (x,y)
1.375"
3.000"
2.800"
4.500"
5.00
0"
2.62
5"
6.000"
2.250"
1.31
3"
1.375"
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3)
0.3215", 0.325" DEPTH for STEEL INSERTTYP (3)
Ø0.313" THRU [SEE SECTION A/B]TYP (4)
Ø0.500" 0.325" DEPTH [SEE SECTION A/B]TYP (4)
VIEW
4 - 20 SCREW
EXTRUDER NOSE CONEFACEMATERIAL:
NOTES:DRAWN AS BUILT WITH COORDINATESFOR THRU HOLE LOCATIONS
05.18.2015-1
DESCRIPTION:
HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
06.02.2015
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
Drawn By: Kevin Hinz; <[email protected]>; 1:1tel: 606.271.7330
DESCRIPTIONREV.-
DATE
SCALE:
COMPONENT:
6" ALUMINUM ROUND
NOSE - 01-1Original Machining DrawingDrawing as Fabricated
HARVARD GRADUATE SCHOOL OF DESIGN
1 COUNT - Beginning 6" Round
Ø0.600" 3" DEPTH [SEE SECTION A/B]TYP (4)
2.605"
2.605"
Ø6.000"
Ø1.500"
Ø3.500"
Ø6.000" Ø4.000" SEE MID SECTION
Ø0.313"THRU [SEE SECTION A/B]TYP (4)
6.000"VIEW
ECTION
MATERIAL:
DATEEXTRUDER NOSE CONETAIL
DESCRIPTION: COMPONENT:
SCALE:
PART COUNT
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
NOTES:
-106.02.2015HARVARD GRADUATE SCHOOL OF DESIGN05.18.2015
1:1
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] DESCRIPTIONREV.- Original Machining Drawing
Drawing as Fabricated1 COUNT - Beginning 6" Round
HARVARD GRADUATE SCHOOL OF DESIGN
NOSE - 026" ALUMINUM ROUND
3.983"
3.81
9"
1.122"
2.243"
1.991"
2.730"
0.875"
1.00
0"
2.828"
6.000" initial diameter
1.750"
1.750"
1.750"
0.75
9"
3.505"
0.32
5"
66.00°
24.00°
24.00°
5.656"
1.08
9"1.
971"
0.750"
0.3215", 0.325" DEPTH for 3/8" STEEL INSERTTYP (3) SEE NOSE-02 FOR DETAIL
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3) SEE NOSE-02 FOR DETAIL
SECTION LINE
SECTION LINE
or 1/4 - 20 SCREW02 FOR DETAIL
COMPONENT:DATE
NOTES:
MATERIAL:
PART COUNT
SCALE:
EXTRUDER NOSE CONEMID-SECTION
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
DESCRIPTION:
-106.02.2015HARVARD GRADUATE SCHOOL OF DESIGN05.18.2015
1:1
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] DESCRIPTIONREV.- Original Machining Drawing
Drawing as Fabricated
HARVARD GRADUATE SCHOOL OF DESIGN
MID SECTION6" ALUMINUM ROUND
1 COUNT - Beginning 6" Round
1.688"
1.10
0"
1.122" 0.997"
3.375"
1.993" ID
1.375"
2.243" OD
1.374"
1.993"1.750"
0.94
8"
66.00°
24.00°
0.875"
0.997"
1.506"0.906"
0.300"
0.753"
0.25
0"
0.54
6"1.
152"
1.94
8"
0.378" 0.378"
BEGINNING 3.5" ALUMINUM ROUND
SYNTHETIC INSERT
.9060" DIA, TAP 3/4 NPT
0.2010" DIA, TAP 1/4 - 20 SCREW
TYP (3)
0.1250" THICK
0.2660" DIA, THRU 1/4 - 20 SCREWTYP (3)
MATERIAL: 2.25" OD SYNTHETIC TUBE,
NOTES:SYNTHETIC INSERT TO FIT IN NOSE CONESEE DRAWINGS: NOSE 01 & NOSE 01-1
PART COUNT06.02.2015
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] REV.
Drawn By: Kevin Hinz; <[email protected]>;
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330
-DATE
SCALE:
COMPONENT:DESCRIPTION:EXTRUDER NOSE CONEFACE
1:1
DESCRIPTIONOriginal Machining Drawing
HARVARD GRADUATE SCHOOL OF DESIGN
2 SEPARATE PARTS / 2 SEPARATE MATERIALS
3.5" ALUMINUM ROUND
NOSE TIP - 01
0.93
8"
0.250"
1.18
8"
2.500"
4.000"
4.500"
0.500"2.000"
MODIFY HERE:TO SUPPORT TENSION ROD
MODIFY HERE:TO SUPPORT TENSION ROD
EXISITNG COMPONENT
WORK FROM THIS EDGE
NOTES:ALUMINUM SUPPORT IS EXISTINGMODIFICATION IS TO PROVIDE RELIEF FOR TENSION ROD
REV.06.02.2015 -
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
1:1HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
tel: 606.271.7330
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:DESCRIPTION
Drawn By: Kevin Hinz; <[email protected]>;
EXTRUDER CYLINDER SUPPORT
HARVARD GRADUATE SCHOOL OF DESIGN
Original Machining Drawing3 PARTS TO MODIFY
EXISTING
SUPPORT - 01
0.37
3"
1.188"
0.500" 0.756"
3.54
3"
0.188"
0.74
5"
0.37
3"
0.37
0"
0.74
5"
1.54
0"
0.625"
3.08
0"
1.000"
0.506"
0.76
0"
3.08
0"
0.506"
0.250"
0.250"
0.431"
1.047" APRX
0.400"
3.42
0"
THRU HOLE FOR 1/4" PINSNUG FIT
EXISTING ACME SCREW
SOCKET FOR 3/4 ACME SCREW
BEGINNING 3.5" ALUMINUM ROUND
TAP FOR 5/16-18
5/16-18 x 3/8" HEX SCREW
1/4" x 1.6" PIN, STEEL
1.5" FENDER WASHER THRU HOLE FOR 1/4" PINTIGHT FITEXISTING PLUNGER CUP
DESCRIPTION--1
06.02.201506.04.2015
EXTRUDER CYLINDER PLUNGER
SCALE:
DATE DESCRIPTION:
NOTES:ACME SCREW TO BE PINNED TO PLUNGERPLUNGER CUP TO BE SCREWED TO PUNGER
MATERIAL: 1:1
COMPONENT:REV.
tel: 606.271.7330Drawn By: Kevin Hinz; <[email protected]>;
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
HARVARD GRADUATE SCHOOL OF DESIGN
PART COUNT
HARVARD GRADUATE SCHOOL OF DESIGN
Original Machining Drawing5 SEPARATE PARTS:2 PARTS TO FABRICATE3 PARTS EXISTING
3.5" ALUMINUM ROUND
PLUNGER - 01REVISED Machining Drawing
2.62
5"
5.00
0" 1.25
0"
1.250"
Ø0.313"THRU [SEE SECTION DETAIL]TYP (4)
1.31
3"
4.500"
4.500"
Ø0.500" 0.325" DEPTH [SEE SECTION DETAIL]TYP (4)
0.3215", 0.325" DEPTH for STEEL INSERTTYP (3)
0.2010", 1" DEPTH for 1/4 - 20 SCREWTYP (3)
Ø6.000" Ø4.000" SEE NOSE 01
Ø0.600" 3" DEPTH [SEE DETAIL]TYP (4)
Ø0.313"THRU [SEE DETAIL]TYP (4)
2.605"
2.605"
Ø6.000"
Ø1.500"Ø3.500"
5.00
0"
0.31
3"
0.325"
4.000"
0.675" 3.000"
0.50
0"
2.62
5"
6.00
0"1.31
3"1.
313"
0.60
0"
SECTION B
SECTION B
SECTION B
1.00
0"0.
675"
3.00
0"
4.00
0"
0.50
0"
0.32
5"
2.250"2.250"
SECTION A
PART COUNTREV.
1:2
EXTRUDER NOSE CONESECTIONS
COMPONENT:DATE
SCALE:DRAWN BY:
DESCRIPTION DESCRIPTION:
KEVIN HINZ
tel: 606.271.733005.18.2015
Kevin Hinz; <[email protected]>;-
MATERIAL:
SECTION A & B 1
6" ALUMINUM ROUND
Original Machining Drawing
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] HARVARD GRADUATE SCHOOL OF DESIGN
4.500"
1.00
0"
0.67
5"3.
000"
4.00
0"
0.50
0"
0.32
5"
2.250"2.250"
SECTION A
SECTION B
SECTION B
PART COUNT
SCALE: 1:1DRAWN BY:
Kevin Hinz; <[email protected]>;05.18.2015
tel: 606.271.7330
KEVIN HINZ
EXTRUDER NOSE CONESECTION A
DESCRIPTIONREV.-
DATE DESCRIPTION:
MATERIAL:
COMPONENT:Original Machining Drawing SECTION A
HARVARD GRADUATE SCHOOL OF DESIGNMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S] 6" ALUMINUM ROUND
1
5.00
0"
0.31
3"
0.325"
4.000"
0.675" 3.000"
0.50
0"
2.62
5"
6.00
0"
1.31
3"1.
313"
0.60
0"
SECTION B
SECTION B
SECTION B
PART COUNTDESCRIPTION
1:1DRAWN BY:
DATE COMPONENT:
SCALE:
EXTRUDER NOSE CONESECTION B
DESCRIPTION:
KEVIN HINZ
tel: 606.271.733005.18.2015
Kevin Hinz; <[email protected]>;-REV.
MATERIAL:HARVARD GRADUATE SCHOOL OF DESIGN
SECTION B 1
6" ALUMINUM ROUND
Original Machining Drawing
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
0.23
6"
0.280"
D0.280"
0.675"
0.09
8"
0.669"
1.14
2"
D0.944"
2.79
5"
2.5mm groove for 2.5 x 17mm oring
0.945"
D0.704" for 1/2" NPT TAP
1.65
4" 1.10
2"
PART COUNT09.14.2015 AUGER TRANSMISSION
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
HARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
1:1
NOTES:INCH DRAWING
DESCRIPTIONREV.-
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:
HARVARD GRADUATE SCHOOL OF DESIGN
1 COUNT - Beginning 1.25" RoundTRANSMISSION1.25" Nylon Rod
Original Machining DrawingINCH
29m
m
6mm
groove for 2.5 x 17mm oring2.5m
m
17.15
28m
m
17.86mm DIA for 1/2" NPT TAP
7.10mm
24mm
D7.10mm
42m
m
19mm
71m
m
D24mm
tel: 606.271.7330
AUGER TRANSMISSIONMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
Drawn By: Kevin Hinz; <[email protected]>;
NOTES:METRIC DRAWING
09.14.2015DESCRIPTION:
HARVARD GRADUATE SCHOOL OF DESIGN
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION PART COUNT
1:1MATERIAL:1.25" Nylon Rod
TRANSMISSIONHARVARD GRADUATE SCHOOL OF DESIGN
Original Machining Drawing 1 COUNT - Beginning 1.25" RoundMETRIC
Ø0.165" TAP M5 x .8
Ø0.217" #19 DRILLTHRU for M5 x .8 SCREWTYP 6
Ø0.165" TAP M5 x .8
Ø0.217" #19 DRILLTHRU for M5 x .8 SCREWTYP 6
4.35
0"
2.73
6"
2.000"
(X,Y) = (0.7849,-1.0025)
(X,Y) = (0.0,1.8524)
1.000"
(X,Y) = ( -0.7849,-1.0025)
(X,Y) = ( -0.5568,0.5568)
45.0
0°
(X,Y) = ( 0.5568,-0.5568)(X,Y) = ( -0.5568,-0.5568)
(X,Y) = ( 0.5568,0.5568)
(X,Y) = (-0.0,0.9285)
1.61
4"
REV. DESCRIPTIONMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
HARVARD GRADUATE SCHOOL OF DESIGN
Drawn By: Kevin Hinz; <[email protected]>; 1:1
PART COUNT
tel: 606.271.7330
-
NOTES:
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:09.14.2015 AUGER TRANSMISSIONOriginal Machining Drawing
...1 COUNT - Beginning 5/16" x 2" x 6" Aluminum Bar Stock
0.3125" Aluminum BarHARVARD GRADUATE SCHOOL OF DESIGN
ATI: QC-11 INTERFACE
full step-up(not possible)
1.29 mm^2
50% InFill
1.7mm x 0.85mm
5-Axis Solution50% InFill
50% step-up
1.29 mm^21.29 mm^2
5-Axis SolutionSolid InFill
1.29 mm^2
Step-Over x Step-Up: 1.7mm x 1.7mm2.27 mm^2 1.29 mm^2
Solid Configuration
1.7mm x 0.85mm 1.7mm x 0.85mm
1.7mm x 0.85mm
1.7mm x 0.85mm
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
HARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]10.06.2015 MICRO EXTRUSION
2:1
DESCRIPTION:
MATERIAL:
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION NOTE
AXONOMETRIC DIAGRAM TOOLPATH PARAMETERSHARVARD GRADUATE SCHOOL OF DESIGN
...
MISC CLAY BODY
Length
DIA
Die
Ram Velocity
Extrudate Velocity Extrudate
Barrel
Ram
Die entry region
Drawn By: Kevin Hinz; <[email protected]>;
DESCRIPTION:PISTON EXTRUDER DIAGRAM DIAGRAMATIC DRAWING OF PISTON-TYPE EXTRUDER11.28.2015
NOTE
SCALE: NO SCALE
HARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]
NOTES:
tel: 606.271.7330 NONE
DESCRIPTIONREV.-
DATE
SCALE:
COMPONENT:
MATERIAL:HARVARD GRADUATE SCHOOL OF DESIGN
AXONOMETRIC DIAGRAM... PISTON EXTRUDER
0.800"
24.700" CRITICAL MAX
0.188"
31.000" APROX
1.000"
DIA: 0.250"
28.700" MAX
0.800"
0.58
5"
1.500"
25.500" MAX
3.500"
5.500"
2.000"2.000" APX
0.56
0"
POLYCARBONATE TUBE, 27"x4"OD1.5" FENDER WASHER
5/16-18 x 3/8" HEX SCREW
EXISTING PLUNGER CUP
MOTOR HOUSING
DESCRIPTIONREV. PART COUNT | DESCRIPTIONEXTRUDER DRIVE SCREW
tel: 606.271.7330
HARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]10.22.2015
1:1Drawn By: Kevin Hinz; <[email protected]>;
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:DATE-
FOR DUPLICATE SECTION C6" ALUMINUM ROUNDHARVARD GRADUATE SCHOOL OF DESIGN
Original Lathe Drawing 1 PARTPress Fit Existing Plunder to Replacement Drive Screw Housing drawn to show placementNOTE: Length is Sectioned to fit page
Layer Alignment
1.29 mm^20.85 mm stepover
Excessive Material
Low Flow
1.29 mm^2
Solid Configuration
Infill Configuration
1.29 mm^2
Controlled Deposition
Low-No Compression
1.29 mm^2
Under Compression
High Flow
Over Compression
Increased StepOver
1.29 mm^2
Collapsed Structure
Ideal Contact
Layer Compression
Gap
Surface Drop
Pulled Coil
Pushed Coil
SlumpGap
2-Perimeters for Example
Graduated Layer Building
COMPONENT:
Drawn By: Kevin Hinz; <[email protected]>; 2:1
12.21.2015 MICRO EXTRUSIONHARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL:
NOTE
SCALE:
DATE-REV. DESCRIPTION DESCRIPTION:
tel: 606.271.7330 HARVARD GRADUATE SCHOOL OF DESIGN
...AXONOMETRIC DIAGRAM TOOLPATH PARAMETERS II
MISC CLAY BODY
5-Axis Step-Over
0.5*Bead Diameter = Nozzle Width
Bead Diameter = Nozzle Width
Interlocked Layers
Standard Flow Rate
Increased Flow Rate
3-Axis Step-Over
25% Overlay
Simple Compression Zone
Pulled Coil
Complex Compression Zone
NOTE
Drawn By: Kevin Hinz; <[email protected]>; 2:1tel: 606.271.7330
HARVARD GRADUATE SCHOOL OF DESIGNMICRO EXTRUSION12.21.2015 -
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:DESCRIPTIONREV.
...
HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
AXONOMETRIC DIAGRAM 5-AXIS FLOW
40.00°
anticipated
60.00° MIN
Cantilever Potential25% OverlayLimited Cantilever Potential
5-Axis3-Axis
Unsupported OverhangUnsupported Overhang
Articulated Tooling
Integrated Structure
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330 2:1
12.21.2015NOTE
Drawn By: Kevin Hinz; <[email protected]>;
MICRO EXTRUSION
MATERIAL:
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION DESCRIPTION:
...AXONOMETRIC DIAGRAM
MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
5-AXIS CANTLEVER
Layer Alignment
1.29 mm^20.85 mm stepover
Excessive Material
Low Flow
1.29 mm^2
Solid Configuration
Infill Configuration
1.29 mm^2
Controlled Deposition
Low-No Compression
1.29 mm^2
Under Compression
High Flow
Over Compression
Increased StepOver
1.29 mm^2
Collapsed Structure
Ideal Contact
Layer Compression
Gap
Surface Drop
Pulled Coil
Pushed Coil
SlumpGap
2-Perimeters for Example
Graduated Layer Building
COMPONENT:
Drawn By: Kevin Hinz; <[email protected]>; 2:1
12.21.2015 MICRO EXTRUSIONHARVARD GRADUATE SCHOOL OF DESIGN
MATERIAL:
NOTE
SCALE:
DATE-REV. DESCRIPTION DESCRIPTION:
tel: 606.271.7330 HARVARD GRADUATE SCHOOL OF DESIGN
...AXONOMETRIC DIAGRAM TOOLPATH PARAMETERS II
MISC CLAY BODY
Density
Resolution
Digital
Porosity
2:1
MICRO EXTRUSIONHARVARD GRADUATE SCHOOL OF DESIGN
SCALE:
DESCRIPTION NOTE
tel: 606.271.7330
DATE12.21.2015
COMPONENT:
MATERIAL:
DESCRIPTION:REV.
Drawn By: Kevin Hinz; <[email protected]>;
- AXONOMETRIC DIAGRAM... TOOLPATH PARAMETERS III
HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
5-Axis Step-Over
0.5*Bead Diameter = Nozzle Width
Bead Diameter = Nozzle Width
Interlocked Layers
Standard Flow Rate
Increased Flow Rate
3-Axis Step-Over
25% Overlay
Simple Compression Zone
Pulled Coil
Complex Compression Zone
NOTE
Drawn By: Kevin Hinz; <[email protected]>; 2:1tel: 606.271.7330
HARVARD GRADUATE SCHOOL OF DESIGNMICRO EXTRUSION12.21.2015 -
DATE
SCALE:
COMPONENT:
MATERIAL:
DESCRIPTION:DESCRIPTIONREV.
...
HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
AXONOMETRIC DIAGRAM 5-AXIS FLOW
40.00°
anticipated
60.00° MIN
Cantilever Potential25% OverlayLimited Cantilever Potential
5-Axis3-Axis
Unsupported OverhangUnsupported Overhang
Articulated Tooling
Integrated Structure
HARVARD GRADUATE SCHOOL OF DESIGN
tel: 606.271.7330 2:1
12.21.2015NOTE
Drawn By: Kevin Hinz; <[email protected]>;
MICRO EXTRUSION
MATERIAL:
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION DESCRIPTION:
...AXONOMETRIC DIAGRAM
MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
5-AXIS CANTLEVER
5-Axis Tooling
c-B
c-A
c-B
c-A
Drawn By: Kevin Hinz; <[email protected]>; NO SCALEHARVARD GRADUATE SCHOOL OF DESIGN
NOTE5-AXIS SURFACE ARTICULATION
tel: 606.271.7330
12.21.2015DESCRIPTION:
MATERIAL:
COMPONENT:
SCALE:
DATE-REV. DESCRIPTION
AXONOMETRIC DIAGRAM
MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
... PROTOTYPICAL BLOCK BLOCK IS A TEST SUBJECT APPROXIMATING LIKELY ENCOUNTERED GEOMETRIES
Section c-A5-Axis Tooling
REV.
HARVARD GRADUATE SCHOOL OF DESIGN
NOTE
Drawn By: Kevin Hinz; <[email protected]>; tel: 606.271.7330
12.21.2015 5-AXIS SURFACE ARTICULATION
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HARVARD GRADUATE SCHOOL OF DESIGN MISC CLAY BODY
AXONOMETRIC DIAGRAM... SECTION c-A EXPERIMENTAL SURFACE ARTICULATION
Section c-B5-Axis Tooling
Drawn By: Kevin Hinz; <[email protected]>; 2:1HARVARD GRADUATE SCHOOL OF DESIGN
NOTE5-AXIS SURFACE ARTICULATION
tel: 606.271.7330
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AXONOMETRIC DIAGRAM
MISC CLAY BODYHARVARD GRADUATE SCHOOL OF DESIGN
... SECTION c-B EXPERIMENTAL SURFACE ARTICULATION
11.28.2015
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HARVARD GRADUATE SCHOOL OF DESIGN
Articulated Print Nozzle Orientated Toolpath Plan Orientated Toolpath Axon
Cylindrical Print Nozzle[Orintation not Significant]
...AXONOMETRIC DIAGRAM 6-AXIS PRINTING
Ejection Nozzle
Deposited Layers(modeled part)Control Surface
11.28.2015
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HARVARD GRADUATE SCHOOL OF DESIGN
...AXONOMETRIC DIAGRAM LAYER DEPOSITION
Stainless or AluminumMounting Bracket [Fan]
1ct- 2 or 3mm x 18ID O-Ring
Aluminum or Stainless Backing Plate
Auger: 1/4" Lag Screw3.5" Length, 2.5" Tooth
2ct.- 18-8 Stainless Steel Threaded Stand-Off 4-40 3/16" Hex, 3/4" Length
1ct.- 42mm NEMA17 Stepper Motor
NOTE: ID is about 0.1mm greater than auger DIA
2ct- Stainless 4-40 x 1.5-1.75" Length Socket Cap Screw
1ct- 50ml or 60ml Syringew/ Luer-Lok Tip
2ct.- 0.125" Spring Steel Tension Rod (piano wire)
1ct.- Aluminum Flex Shaft CouplerSized as needed [5mm -to- Auger DIA]
4ct.- Stainless Steel M3 x 18mm Socket Cap Screw
1ct.- 19mmOD x 6mmID x 6mm Bearingor other according to Auger Dimensions
NOTE11.28.2015
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HARVARD GRADUATE SCHOOL OF DESIGN
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AXONOMETRIC DIAGRAM
HARVARD GRADUATE SCHOOL OF DESIGN
... AUGER PARTS DEFINITION
1
2
3
4
56
1
2
4
5
3
1
2
5
3