Robotic Free-Oriented Additive Manufacturing Technique for Thermoplastic Lattice and Cellular Structures (original) (raw)
Related papers
2023
Additive manufacturing, commonly referred to as 3D printing, is a rapidly growing technology that allows for the creation of three-dimensional parts in a fraction of the time required by traditional methods. Conventional 3D printers use either cartesian or delta mechanisms, which are reliable but limited in movement due to the fixed orientation of the tool head. Researchers have been working on using robotic manipulators to create new 3D printing techniques. To accomplish this, they first need to establish a robotic framework for basic 3D printing. This technical brief explains the steps for the implementation of a robotic manipulator for fused deposition modelling (FDM). The proposed approach can help other researchers develop their own robotic 3D printing framework. While many other alternatives can be utilized, the proposed methodology is not intended to be unique or optimized. However, it provides important technical details that can help to expedite the process of establishing new research projects in this field. Additionally, this brief introduces the concept of the "printability index", which can be used to create a map for positioning the build platform in the robot's workspace.
Additive Manufacturing Letters, 2022
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Case Specific Robotic Fabrication of Foam Shell Structures
Proceedings of the 35th International Conference on Education and Research in Computer Aided Architectural Design in Europe (eCAADe) [Volume 2]
Most recent developments in the design of free form shells pursue new approaches in digital fabrication based on material properties and construction-aware design. In this research we proposed an alternative approach based on implementation of expanded polystyrene (EPS), a non-standard material for shells, in the process of industrial robot fabrication that enables fast and precise cutting of building elements. Main motivation for using EPS as a building material was driven by numerous advantages when compared to commonly used materials such as: recycleability, cost-efficiency, high earthquake resistance, durability and short assembly time. We describe case specific fabrication approach based on numerous production constraints (size of the panels, limited robot workspace, in situ conditions) that directly design the process.
Printing Compound-Curved Sandwich Structures with Robotic Multi-Bias Additive Manufacturing
Phygital Intelligence, 2023
has developed a novel method for 3d-printing curved open grid core sandwich structures using a thermoplastic extruder mounted on a robotic arm. This print-on-print additive manufacturing (AM) method relies on the 3d modeling software Rhinoceros and its parametric software plugin Grasshopper with Kuka-Parametric Robotic Control (Kuka-PRC) to convert NURBS surfaces into multi-bias additive manufacturing (MBAM) toolpaths. While several highprofile projects including the University of Stuttgart ICD/ITKE Research Pavilions 2014-15 and 2016-17, ETH-Digital Building Technologies project Levis Ergon Chair 2018, and 3D printed chair using Robotic Hybrid Manufacturing at Institute of Advanced Architecture of Catalonia (IAAC) 2019, have previously demonstrated the feasibility of 3d printing with either MBAM or sandwich structures, this method for printing Compound-Curved Sandwich Structures with Robotic MBAM combines these methods offering the possibility to significantly reduce the weight of spanning or cantilevered surfaces by incorporating the structural logic of open grid-core sandwiches with MBAM toolpath printing. Often built with fiber reinforced plastics (FRP), sandwich structures are a common solution for thin wall construction of compound curved surfaces that require a high strength-to-weight ratio with applications including aerospace, wind energy, marine, automotive, transportation infrastructure, architecture, furniture, and sports equipment manufacturing. Typical practices for producing sandwich structures are labor intensive, involving a multi-stage process including (1) the design and fabrication of a mould, (2) the application of a surface substrate such as FRP, (3) the manual application of a lightweight grid-core material, and (4) application of a second surface substrate to complete the sandwich. There are several shortcomings to this moulded manufacturing method that affect both the formal outcome and the manufacturing process: moulds are often costly and labor intensive to build, formal geometric freedom is limited by the minimum draft angles required for successful removal from the mould, and customization and refinement of product lines can be limited by the need for moulds. While the most common material for this construction method is FRP, our proof-of-concept experiments relied on low-cost thermoplastic using a specially configured pellet extruder. While the method proved feasible for small representative examples there remain significant challenges to the successful deployment of this manufacturing method at larger scales that can only be addressed with additional research. The digital workflow includes the following steps: (1) Create a 3D digital model of the base surface in Rhino, (2) Generate
Robotic Spatial Printing For Designers
2021
This research developed a fully-integrated robotic printing system, using new methods of additive manufacture (AM) that enables users to explore spatially printed structures with increased freedom of geometric complexity. Current AM technologies, such as Fusion Deposition Modelling (FDM), can rapidly translate design ideations into solid forms by precisely depositing consecutive layers of material in coordination with the movements of a robotic platform. Using this method, solid objects are digitally deconstructed into linear toolpaths and physically reconstituted with thermoplastic extrusion equipment; the toolpath becomes the form. To my parents, Deb and Dai, for their unconditional support and encouragement. I would never had made it this far without you. My thanks to Ben, Devon, and John for your resources and technical assistance. Your craftsmanship and generosity has been an inspiration to me. To my friends here and the world over for your steadfast love and support. You raise me up to new heights and make it a joy to pursue your passions.
3D Printing and Additive Manufacturing
This work explores additive manufacturing (AM) of concrete by using a six-axis robotic arm and its use in large-scale, autonomous concrete construction. Concrete AM uses an extrusion method to deposit concrete beads in layers to create a three-dimensional (3D) shape. This method has been found to have many uses and advantages in construction applications. The lack of formwork and autonomous nature of this manufacturing method allows for new geometries and materials to be printed in unsafe or challenging environments. Autonomous construction has been suggested as a method of creating habitats in rapid-response scenarios. This article discusses research toward one such system that could be used to rapidly construct necessary habitats in response to low-resource and emergency situations. This required addressing certain limitations of a six-axis robotic arm platform along with overcoming system challenges to achieve deliverables for NASA's ''3D Printed Habitat Challenge.'' This included system design to increase the build volume, integrate embedding, print non-coplanar sections, and minimize travel moves to address the challenges associated with continuous extrusion of cementitious material. The system was demonstrated by printing a one-third scale habitat, which represents the first 3d-printed fully enclosed structure at an architectural scale without the use of support.
Robotic 3D Printing of Mineral Foam for a Lightweight Composite Concrete Slab
CAADRIA proceedings
This paper presents the design and fabrication of a lightweight composite concrete slab prototype using 3D printing (3DP) of mineral foams. Conventionally, concrete slabs are standardized monolithic elements that are responsible for a large share of used materials and dead weight in concrete framed buildings. Optimized slab designs require less material at the expense of increasing the formwork complexity, required labour, and costs. To address these challenges, foam 3D printing (F3DP) can be used in construction as demonstrated in previous studies for lightweight facade elements. The work in this paper expands this research and uses F3DP to fabricate the freeform stay-in-place formwork components for a material-efficient lightweight ribbed concrete slab with a footprint of 2 x 1.3 m. For this advancement in scale, the robotic fabrication and material processing setup is refined and computational design strategies for the generation of advanced toolpaths developed. The presented composite of hardened mineral foam and fibre-reinforced ultra-high-performance concrete shows how custom geometries can be efficiently fabricated for geometrically complex formwork. The prototype demonstrates that optimized slabs could save up to 72% of total concrete volume and 70% weight. The discussion of results and challenges in this study provides a valuable outlook on the viability of this novel fabrication technique to foster a sustainable and resourceful future construction culture.
Robotic Fabrication in Architecture, Art and Design 2016, 2016
This paper discusses the development of an informed Design-to-Robotic-Production (D2RP) system for additive manufacturing to achieve performative porosity in architecture at various scales. An extended series of experiments on materiality, fabrication and robotics were designed and carried out resulting in the production of a one-to-one scale prototype. In this context, design materiality has been approached from both digital and physical perspectives. At digital materiality level, a customized computational design framework is implemented for form finding of compression only structures combined with a material distribution optimization method. Moreover, the chained connection between parametric design model and robotic production setup has led to a systematic study of certain aspects of physicality that cannot be fully simulated in the digital medium, which then establish a feedback loop for underrating material behaviors and properties. As a result, the D2RP system proposes an alternative method of robotic material deposition to create an informed material architecture.
Volume 2B: 44th Design Automation Conference, 2018
Manufacturing processes for the fabrication of complex geometries involve multi-step processes when using conventional machining techniques with material removal processes. Additive manufacturing processes give leverage for fabricating complex geometric structures compared to conventional machining. The capability to fabricate 3D lattice structures is a key additive manufacturing characteristic. Most conventional additive manufacturing processes involve layer based curing or deposition to produce a three-dimensional model. In this paper, a threedimensional lattice structure generator for multi-plane fused deposition modeling printing was explored. A toolpath for an input geometric model with an overhang structure was able to be generated. The input geometric model was able to be printed using a six degree of freedom robot arm platform. Experimental results show the achievable capabilities of the 3D lattice structure generator for use with the multi-plane platform.
Robotic Multi-dimensional Printing Based on Structural Performance
Robotic Fabrication in Architecture, Art and Design 2016, 2016
This paper discusses a robotic multi-dimensional printing design methodology based on a material's structural performance. Through research on the process of a spider's behavior, e.g., spinning and weaving, the designers simulate natural construction principles and apply them to the optimization of traditional 3D printing techniques. A 6-axis robot is programmed to carry a customized printing end effector to create free-standing geometries in space. The structural behavior of the design is optimized through the consistent negotiation between material analysis and structural simulation in both virtual and physical environment, together with the implementation of sensor input and real-time feedback between construction tools and simulation interfaces. The printing tools are designed with additional extruders and nozzles of various dimensions to adapt to different materials and design requirements. In this way, a flexible and adaptive additive manufacturing methodology is established, which integrates the material and structural information with design initiatives. Displaying a high degree of spatial and structural complexity, the alliance between 3D printing and robotic technology opens new possibilities to sophisticated architectural structures.