Design Methods for Large Scale Printing | ECAADE 2015

The International Journal of Advanced Manufacturing Technology, 2019

Additive manufacturing (AM) enables the direct manufacture of complex geometries with unique engineering properties. In particular, AM is compatible with topology optimisation (TO) and provides a unique opportunity for optimal structural design. Despite the commercial opportunities enabled by AM, technical requirements must be satisfied in order to achieve robust production outcomes. In particular, AM requires support structures to fabricate overhanging geometry and avoid overheating. Support generation tools exist; however, these are generally not directly compatible with the voxel-based representation typical of TO geometries, without additional computational steps. This research proposes the use of voxel-based Cellular automata (CA) as a fundamentally novel method for the generation of AM support structures. A number of CA rules are proposed and applied with the objective of generating robust support structures for an arbitrary TO geometry. Relevant CA parameters are assessed in terms of structure manufacturability, including sequential and random CA, rotation of the cellular array, and alternate CA boundary rules, including permutations not previously reported. From this research, CA with complex cell arrangements that provide robust AM support for TO geometries are identified and demonstrated by manufacture with selective laser melting (SLM) and fused deposition modelling (FDM). These CA may be automatically applied to enable TO geometries to be directly fabricated by AM, thereby providing a unique, and commercially significant, design for AM (DFAM) capability.

2021

This research posits an innovative process of embedding carbon fibre as the primary structure within large-scale polymer 3D printed intricate architectural forms. The design and technical implications of this research are explored and demonstrated through two proto-architectural projects, Cloud Affects and Unclear Cloud, developed by the RMIT Architecture Snooks Research Lab. These projects are designed through a tectonic approach that we describe as a super composite – an approach that creates a compression of tectonics through algorithmic self-organisation and advanced manufacturing. Framed within a critical view of the lineage of polymer 3D printing and high tech fibres in the field of architectural design, the research outlines the limitations of existing robotic processes employed in contemporary carbon fibre fabrication. In response, the paper proposes an approach we describe as Infused Fibre Reinforced Plastic (IFRP) as a novel fabrication method for intricate geometries. Thi...

Technological Forecasting and Social Change, 2016

Additive manufacturing (AM), more popularly known as '3D printing', is believed by many commentators to be underpinning a new manufacturing revolution. AM encompasses a broad range of manufacturing process technologies that are emerging to offer the prospect of on-demand, mass personalisation, with more localised, flexible and sustainable production (Hutchings and Martin, 2012; Mortara, 2009; Despeisse and Ford, 2015). Its adoption and implementation could disrupt the organisation of manufacturing and the ways in which companies capture value. In industry, AM is the accepted term, while '3D printing' is commonly used to denote those machines used primarily by home users. The terms are often used interchangeably and both refer to "a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies" (ASTM, 2012). AM is not just a single technology. Instead there are a multitude of different technologies, each at differing levels of technological maturity, offering the option of using different materials, with different quality outputs. Among many classifications of AM, the ASTM propose seven categories depending on how the layers are created: (1) vat photopolymerisation; (2) material jetting; (3) binder jetting; (4) material extrusion; (5) powder bed fusion; (6) sheet; and (7) directed energy deposition.

The Visual Computer, 2019

Lightweight modeling is one of the most important research subjects in modern fabrication manufacturing, and it provides not only a low-cost solution but also functional applications, especially for the fabrication using 3D printing. This approach presents a multi-scale porous structure-based lightweight framework to reduce the weight of 3D printed objects while meeting the specified requirements. Specifically, the triply periodic minimal surface (TPMS) is exploited to design a multi-scale porous structure, which can achieve high mechanical behaviors with lightweight. The multi-scale porous structure is constructed using compactly supported radial basis functions, and it inherits the good properties of TPMS, such as smoothness, full connectivity (no closed hollows) and quasi-self-supporting (free of extra supports in most cases). Then, the lightweight problem utilizing the porous structures is formulated into a constrained optimization. Finally, a strength-to-weight optimization method is proposed to obtain the lightweight models. It is also worth noting that the proposed porous structures can be perfectly fabricated by common 3D printing technologies on account of the leftover material, such as the liquid in SLA, which can be removed through the fully connected void channel.

International Journal of Current Engineering and Technology, 2018

A class of technologies referring to Rapid Prototyping (RP) or Additive or Layer Manufacturing or 3D Printing allows designers to quickly create tangible prototype instead of using two dimensional pictures. This technology produces models and prototype parts from 3D CAD model data created from 3D object digitizing systems. Rapid Prototyping forms parts by joining together liquid, powder or sheet materials. Physical models are built using three basic stages: pre-processing, building, post-processing. Pre-processing consists of generation of CAD model, convert into STL format and slice the STL files into cross sectional layers. In building process, construction of model takes place one layer atop another. Post process consists of cleaning and finishing the final model. Common types of Rapid Prototyping technologies popular in industry are: Steriolithography, Fused Deposition Modeling, Selective Laser Sintering, Laminated Object Manufacturing,3 D Printing. The selection of the processe...

Macromolecular Materials and Engineering, 2016

Current three-dimensional (3D) printing techniques enable the fabrication of complex multifunctional structures that are unimaginable in conventional manufacturing. In this Perspective, we outline recent progress in materials and manufacturing and propose challenges and opportunities for the future development of 3D printing of functional materials. The success of future 3D printing relies not only on multifunctional materials and printing techniques but also on smart design of complex systems. Engineers need to understand advanced materials, additive manufacturing, and, more importantly, creative design. Fortunately, we can learn from many structures that exist in nature and adapt them to engineered structures.

2009

This article introduces a design approach for generating complex geometries, especially for the purpose of additive manufacturing large physical objects with Fused Filament Fabrication process. The case studies are focused on the process for the design and 3D print of functional furniture as a single piece in 1:1 scale inspired by natural phenomena such as the capillary bridges. By interactively controlling the geometry, as one continuous element in equilibrium, dynamic relaxation using particle spring systems with different warps and wefts forces is used to adjust geometry and overhangs, balancing internal structure, economizing material and travelling time. The benefits of programming the curves with forces and printing paths can enhance the workflow of design directed especially for fabrication. The Radiolaria and Hyperboloid Series of furniture are presented here as an outcome of this research.