Brick Geometries: 5-Axis Additive Manufacturing for...

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


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


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


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


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.


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


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

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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

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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



DESCRIPTION

SCALE:


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


REV.-

NOTEDESCRIPTION DESCRIPTION:

tel: 606.271.7330

MATERIAL:

01.01.2016

1:200

PLAN DIAGRAM PLANMISC CLAY BODY

...


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


Mortar

Tension Tie

1.0 Block

Alternate Connetion

K value

Center Point

Scale 1:100

Inset

Scale 1:10

0.7 2.0


R12.8313m


Mortar Joint

Ground Tie

Scale 1:50



0.5

Dome Organization

Tension Cable

Connection

Tension Tie

1.0 2.0


Arch Center-Line

Saddle Joint

Alternate Connetion

~1.7m

1m

~1.7m

8.25

m

Alternate Connetion

Inset


Mortar

Tension Tie

1.0 Block

Alternate Connetion

K value

Center Point

Scale 1:100

Inset

Scale 1:10

0.7 2.0


R12.8313m


Mortar Joint

Ground Tie

Scale 1:50



0.5

Dome Organization

Tension Cable

Connection

Tension Tie

1.0 2.0


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

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...

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


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:


PART COUNT

06.02.2015


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


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


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


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)



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]>;



PART COUNT


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"


EXISTING ACME SCREW



TAP FOR 5/16-18

5/16-18 x 3/8" HEX SCREW



DESCRIPTION--1

06.02.201506.04.2015


SCALE:

DATE DESCRIPTION:


MATERIAL: 1:1

COMPONENT:REV.




PART COUNT



3.5" 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


DESCRIPTION:


1:1


Drawing as Fabricated


MID SECTION6" ALUMINUM ROUND


3.983"

3.81

9"

1.122"

2.243"

1.991"

2.730"

0.875"

1.00

0"

2.828"


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"



SECTION LINE

SECTION LINE


COMPONENT:DATE

NOTES:

MATERIAL:

PART COUNT

SCALE:



DESCRIPTION:


1:1






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"


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.



tel: 606.271.7330

-DATE

SCALE:

COMPONENT:DESCRIPTION:EXTRUDER NOSE CONEFACE

1:1

DESCRIPTIONOriginal Machining Drawing


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"


SYNTHETIC INSERT

.9060" DIA, TAP 3/4 NPT

0.2010" DIA, TAP 1/4 - 20 SCREW

TYP (3)

0.1250" THICK








tel: 606.271.7330

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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



Stainless or AluminumMounting Bracket [Fan]



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]


SCALE: 1:1


REV.-

DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:

AS NOTED

PART COUNTAXONOMETRIC DIAGRAM

MULTI

AUGER DIAGRAM...



30cc Syringe w/ Luer-Lock Tip



1ct.- 19mmOD x 6mmID x 6mm Bearing

2ct.- 18-8 Stainless Steel Threaded Stand-Off 4-40 3/16" Hex, 3/4" Length


1ct- 2 or 3mm x 18ID O-Ring



12mm Push-To-Connect Gas Fitting





tel: 606.271.7330 NONE

AUGER EXTRUDERMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]


NOTES:

10.06.2015

MATERIAL:

COMPONENT:

SCALE:

DATE-REV. DESCRIPTION PART COUNTDESCRIPTION:

... 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

1

2

3

4

56

1

2

4

5

3

1

2

5

3

“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

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 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



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

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

NOTE


HARVARD GRADUATE SCHOOL OF DESIGNMICRO EXTRUSION12.21.2015 -

DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:DESCRIPTIONREV.

...


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


11.28.2015

NONE

NONE

NOTES:


COMPONENT:

SCALE:




SCALE: NO SCALE

NOTE



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



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


Rotation Rate



NOTE01.16.2016

MATERIAL:

NONE

1:16

NOTES:


SCALE:


3D PRINTER DIAGRAM

tel: 606.271.7330

MATERIAL FLOW...


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

2:1

MICRO EXTRUSIONHARVARD GRADUATE SCHOOL OF DESIGN

SCALE:

DESCRIPTION NOTE

tel: 606.271.7330

DATE12.21.2015

COMPONENT:

MATERIAL:

DESCRIPTION:REV.


- AXONOMETRIC DIAGRAM... TOOLPATH PARAMETERS III


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


tel: 606.271.7330 2:1

12.21.2015NOTE


MICRO EXTRUSION

MATERIAL:

COMPONENT:

SCALE:



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.

1

2

3

4

56

1

2

4

5

3

1

2

5

3

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

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:


AXONOMETRIC DIAGRAM


... 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

Drawn By: Kevin Hinz; <[email protected]>; 2:1HARVARD GRADUATE SCHOOL OF DESIGN


tel: 606.271.7330


MATERIAL:

COMPONENT:

SCALE:


AXONOMETRIC DIAGRAM


... SECTION c-B EXPERIMENTAL SURFACE ARTICULATION

Section c-A5-Axis Tooling

REV.


NOTE


12.21.2015 5-AXIS SURFACE ARTICULATION

2:1

-DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:DESCRIPTION


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.

1

2

3

4

56

1

2

4

5

3

1

2

5

3

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.


Design Proposal

Night view.


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

REV. DESCRIPTION

NO SCALE


tel: 606.271.7330

NOTE


DESCRIPTION:

MATERIAL:


COMPONENT:

SCALE:



...

Alternate Connetion

Inset

Inset


AssemblySequence

~1.7m

1m

~1.7m

8.25

m

Alternate Connetion

Inset


Mortar

Tension Tie

1.0 Block

Alternate Connetion

K value

Center Point

Scale 1:100

Inset

Scale 1:10

0.7 2.0


R12.8313m


Mortar Joint

Ground Tie

Scale 1:50



0.5

Dome Organization

Tension Cable

Connection

Tension Tie

1.0 2.0


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

12.01.2015

NO SCALE



DESCRIPTIONREV.-

DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION: NOTE

ARCH COMPONENTHARVARD GRADUATE SCHOOL OF DESIGN


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



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


Rotation Rate



NOTE01.16.2016

MATERIAL:

NONE

1:16

NOTES:


SCALE:


3D PRINTER DIAGRAM

tel: 606.271.7330

MATERIAL FLOW...


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.


30cc Syringe w/ Luer-Lock Tip



1ct.- 19mmOD x 6mmID x 6mm Bearing






12mm Push-To-Connect Gas Fitting





tel: 606.271.7330 NONE

AUGER EXTRUDERMATERIAL PROCESSEES AND SYSTEMS GROUP [MaP+S]


NOTES:

10.06.2015

MATERIAL:

COMPONENT:

SCALE:

DATE-REV. DESCRIPTION PART COUNTDESCRIPTION:

... AUGER DIAGRAMAXONOMETRIC DIAGRAM

HARVARD GRADUATE SCHOOL OF DESIGN MULTI











12mm Push-To-Connect Air Fitting







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]


SCALE: 1:1


REV.-

DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:

AS NOTED

PART COUNTAXONOMETRIC DIAGRAM

MULTI

AUGER DIAGRAM...


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"





VIEW

4 - 20 SCREW



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


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"





VIEW

4 - 20 SCREW

EXTRUDER NOSE CONEFACEMATERIAL:

NOTES:DRAWN AS BUILT WITH COORDINATESFOR THRU HOLE LOCATIONS

05.18.2015-1

DESCRIPTION:


PART COUNT

06.02.2015



DESCRIPTIONREV.-

DATE

SCALE:

COMPONENT:

6" ALUMINUM ROUND

NOSE - 01-1Original Machining DrawingDrawing as Fabricated



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


SCALE:

PART COUNT


NOTES:


1:1


Drawing as Fabricated1 COUNT - Beginning 6" Round


NOSE - 026" ALUMINUM ROUND

3.983"

3.81

9"

1.122"

2.243"

1.991"

2.730"

0.875"

1.00

0"

2.828"


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"



SECTION LINE

SECTION LINE


COMPONENT:DATE

NOTES:

MATERIAL:

PART COUNT

SCALE:



DESCRIPTION:


1:1






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"


SYNTHETIC INSERT

.9060" DIA, TAP 3/4 NPT

0.2010" DIA, TAP 1/4 - 20 SCREW

TYP (3)

0.1250" THICK








tel: 606.271.7330

-DATE

SCALE:


1:1




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 -


1:1HARVARD GRADUATE SCHOOL OF DESIGN

PART COUNT

tel: 606.271.7330

DATE

SCALE:

COMPONENT:

MATERIAL:



EXTRUDER CYLINDER SUPPORT


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"


EXISTING ACME SCREW



TAP FOR 5/16-18

5/16-18 x 3/8" HEX SCREW



DESCRIPTION--1

06.02.201506.04.2015


SCALE:

DATE DESCRIPTION:


MATERIAL: 1:1

COMPONENT:REV.




PART COUNT



3.5" 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)



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:


KEVIN HINZ

tel: 606.271.733005.18.2015

Kevin Hinz; <[email protected]>;-

MATERIAL:

SECTION A & B 1

6" ALUMINUM ROUND


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.


SECTION B 1

6" ALUMINUM ROUND



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




1:1

NOTES:INCH DRAWING

DESCRIPTIONREV.-

DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:


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]


NOTES:METRIC DRAWING



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]



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



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


DESCRIPTION:PISTON EXTRUDER DIAGRAM DIAGRAMATIC DRAWING OF PISTON-TYPE EXTRUDER11.28.2015

NOTE

SCALE: NO SCALE



NOTES:

tel: 606.271.7330 NONE

DESCRIPTIONREV.-

DATE

SCALE:

COMPONENT:


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


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


Excessive Material

Low Flow

1.29 mm^2

Solid Configuration


1.29 mm^2


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



COMPONENT:



MATERIAL:

NOTE

SCALE:




MISC CLAY BODY

5-Axis Step-Over



Interlocked Layers

Standard Flow Rate

Increased Flow Rate

3-Axis Step-Over

25% Overlay


Pulled Coil


NOTE



DATE

SCALE:

COMPONENT:

MATERIAL:


...



40.00°

anticipated

60.00° MIN


5-Axis3-Axis


Articulated Tooling



tel: 606.271.7330 2:1

12.21.2015NOTE


MICRO EXTRUSION

MATERIAL:

COMPONENT:

SCALE:




5-AXIS CANTLEVER

Layer Alignment


Excessive Material

Low Flow

1.29 mm^2

Solid Configuration


1.29 mm^2


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



COMPONENT:



MATERIAL:

NOTE

SCALE:




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.


- AXONOMETRIC DIAGRAM... TOOLPATH PARAMETERS III


5-Axis Step-Over



Interlocked Layers

Standard Flow Rate

Increased Flow Rate

3-Axis Step-Over

25% Overlay


Pulled Coil


NOTE



DATE

SCALE:

COMPONENT:

MATERIAL:


...



40.00°

anticipated

60.00° MIN


5-Axis3-Axis


Articulated Tooling



tel: 606.271.7330 2:1

12.21.2015NOTE


MICRO EXTRUSION

MATERIAL:

COMPONENT:

SCALE:




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


tel: 606.271.7330


MATERIAL:

COMPONENT:

SCALE:


AXONOMETRIC DIAGRAM


... PROTOTYPICAL BLOCK BLOCK IS A TEST SUBJECT APPROXIMATING LIKELY ENCOUNTERED GEOMETRIES

Section c-A5-Axis Tooling

REV.


NOTE


12.21.2015 5-AXIS SURFACE ARTICULATION

2:1

-DATE

SCALE:

COMPONENT:

MATERIAL:



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


tel: 606.271.7330


MATERIAL:

COMPONENT:

SCALE:


AXONOMETRIC DIAGRAM


... SECTION c-B EXPERIMENTAL SURFACE ARTICULATION

11.28.2015

NONE

NONE

NOTES:


COMPONENT:

SCALE:




SCALE: NO SCALE

NOTE


Articulated Print Nozzle Orientated Toolpath Plan Orientated Toolpath Axon

Cylindrical Print Nozzle[Orintation not Significant]

...AXONOMETRIC DIAGRAM 6-AXIS PRINTING

Ejection Nozzle


11.28.2015

NONE

NONE

NOTES:


COMPONENT:

SCALE:




SCALE: NO SCALE

NOTE










2ct- Stainless 4-40 x 1.5-1.75" Length Socket Cap Screw


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


NOTE11.28.2015

NOTES:

3D PRINTER DIAGRAM

SCALE: NO SCALE


Drawn By: Kevin Hinz; <[email protected]>; NONE

NONEDESCRIPTIONREV.

-DATE

SCALE:

COMPONENT:

MATERIAL:

DESCRIPTION:

tel: 606.271.7330

AXONOMETRIC DIAGRAM


... AUGER PARTS DEFINITION

1

2

3

4

56

1

2

4

5

3

1

2

5

3

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