Manifold assemblages booklet

MANIFOLD ASSEMBLAGES ROBERT STUART-SMITH + OLIVIU LOGOJAN-GHENCIU | AADRL, 2014 | Assad Khan Jaffer, Martina Rosati, Patchara Ruentongdee

MANIFOLD ASSEMBLAGES ROBERT STUART-SMITH + OLIVIU LOGOJAN-GHENCIU | AADRL, 2014 | Assad Khan Jaffer, Martina Rosati, Patchara Ruentongdee

0\\ Table of Contents

1\\ Digital Geometry

3

2\\ Printed Geometry

11

3\\ Virtual Geometry

41

1.1 Geometry modeling process 1.2 2D/3D manifolds 1.3 Selected manifold 1.4 Logic of connections

3 4 8 9

2.1 Joints 2.2 Materials 2.3 Assemblages 2.4 Flexible assemblage 2.5 Optimization 2.6 Volume constraints 2.7 Printing constraints 2.8 Shell geometry assemblage 2.9 Scheme of assemblage

12 13 14 22 24 30 32 34 36

3.1 The spaces 3.2 Nodes and connections 3.3 Unity 3D

42 43 44

MANIFOLD ASSEMBLAGES | AADRL 2014 |

1

Introduction

This research aimed at making the manufacturing process a part of the design process and using the 3d printer as a design tool.

The accuracy of the printed objects depends largely on the experience of the user operating the printer and on the settings of the machines. This largely affected the fabrication process in trying to achieve a similarity in the quality of the printed products.

One of the main goal was to produce a geometry bigger than one printer volume, and some aspects like time, dimensions and joints have been evaluated so that the final geometry represents the optimized solution for these constraints.

Different materials have been used to produce parts of the geometry such as ABS, PLA, Flex PLA, NinjaFlex and Colorfab XT.

2

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1\\ Digital Geometry

1.1 Geometry modeling process

a\\ Setup

b\\ Generation of Istances

The process of design started in conjunction with modeling planar geometries in Maya. This initiated by using polygonal planes to generate a replicating instance, the compound geometry thus produced is a system of similar instances that connects in a manner similar to that of a manifold.

The instances were experimented with in a certain number of ways: 1) 2D setups: the instances were placed in 2 dimensional arrangements, even if the results are three dimensional overlaps.

c\\ Connected geometry

2) 3D setups: the repeating instances were placed at a certain distance from each other in the space and with specific rotations. Explorations were made where the faces were split to produce more vertices.

The final exploration used a solid setup as opposed to a planar setup, the geometry thus created is actually a solid volume hence every iteration made is specifically oriented towards extrusions in a single axis and a multi-axial arrangement.

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3

1.2 2D/3D manifolds The development of geometry, from a 2D setup to a 3D setup.

1\\ setup (2 rectangles)

1\\ setup (4 rectangles)

1\\ setup (4 rectangles)

1\\ setup (4 rectangles)

1\\ setup (6 rectangles)

2\\ 2 instances and 3 connections

2\\ 4 instances and 4 connections

2\\ 6 instances and 2 connections

2\\ 4 instances and 5 connections

2\\ 6 instances and 5 connections

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

4

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1.2 2D/3D manifolds

1\\ setup (6 rectangles)

1\\ setup (5 rectangles)

1\\ setup (8 rectangles)

1\\ setup (8 rectangles)

1\\ setup (8 rectangles)

2\\ 6 instances and 3 connections

2\\ 5 instances and 4 connections

2\\ 8 instances and 2 connections

2\\ 8 instances and 2 connections

2\\ 8 instances and 4 connections

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

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5

1.2 2D/3D manifolds

1\\ setup (2 rectangles)

1\\ setup (2 rectangles)

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

2\\ 2 instances and 4 connections

2\\ 2 instances and 2 connections

2\\ 24 instances and 2 connections

2\\ 24 instances and 4 connections

2\\ 24 instances and 3 connections

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

6

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1.2 2D/3D manifolds

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

1\\ setup (24 rectangles)

2\\ 24 instances and 2 connections

2\\ 24 instances and 3 connections

2\\ 8 instances and 2 connections

2\\24 instances and 2 connections

2\\ 24 instances and 2 connections

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

3\\ Manifold Geometry

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7

1.3 Selected manifold

1\\ setup (24 cube)

2\\ 24 instances and 2 connections

3\\ 24 instances and 3 connections

4\\ manifold geometry

5\\ extrusions on each face

6\\ perspective view of the complex manifold geometry

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8

1.4 Logic of connections

180째

90째

90째

Logic of connection: Every triangle composing the geometry has 6 connections, 3 center to corrner connections (clockwise) and 3 corner to center connections (counter-clockwise).

One triangular component connects to another by two connections, one from the marginal node and one from a central node.

This connection was repeated over 8 components (24 instances) to achieve the final geometry.

From the CENTER to the CORNER From the CORNER to the CENTER MANIFOLD ASSEMBLAGES | AADRL 2014 |

9

10 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2\\ Printed Geometry

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2.1 Joints

Diagram of joint 1 \\

Diagram of joint 2 \\

Diagram of joint 3 \\

Diagram of joint 4 \\

1 \\

2 \\

3 \\

4 \\

1b \\

2b \\

3b \\

4b \\

Sliding joint: which enters on joint from another.

Works well but has a thickness constraint.

Sliding rail joint: it is not rigid enough due to the small scale.

Rigid joint member-socket system: once the joint is fixed, it cannot be removed due to the complexity of the geometry.

Rigid joint: once the joint is fixed, it cannot be removed due to the complexity of the geometry.

A study to achieve connections for the physical models using simple joining connections and develop the final assemblage.

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2.2 Materials

TRIANGLES These external surfaces are printed with rigid PLA, with FDM printer.

ARMS The internal connections are printed with flexible strong filaments.

Even if continuous in material these connections want to create a different space inside the geometry.

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2.3 Assemblages/ Variable A Joint

Elements connection 14 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.3 Assemblages/ Variable A

The geometry is divided into 3 parts according to the instances from digital modelling, connecting each other by member-socket joint.

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2.3 Assemblages / Variable B

Joint

Elements connection 16 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.3 Assemblages/ Variable B

The geometry is divided into 3 parts according to the instances from digital modeling, connecting each other by member-socket joints.

The second material, twisted and bended, creates the arms of the geometry in a continuous material geometry.

The connections do not fit perfectly due to the self-twisting geometry and the complexity of the single pieces constrains the printer settings.

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2.3 Assemblages / Variable C

Joint

18 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.3 Assemblages/ Variable C

The geometry is divided into exterior solid parts and arms connected by a toothed-joint system.

The joint functions quite perfectly but lacks material continuity.

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2.3 Assemblages/ Variable D

Joint

Elements connection 20 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.3 Assemblages/ Variable D

The geometry is divided into 2 parts, the exterior and the interior parts.

The joint is designed along the curve of the geometry.

This experiment is successful as a connecting system but still lacks geometrical continuity.

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2.4 Flexible assemblage

Elements connection

Joint

22 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.4 Flexible assemblage

By combining Varible “C” and “D”, and printing all the arms with flexible material (ninjaflex) it was created a full flxible system of the geometry.

The full geometry is movable and can be squeezed but due to the small gaps between the exterior triangles, the effect of fexible material is not optimized.

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2.5 Optimization 1\\ Full Geometry

2\\ Cut Geometry

3\\ Empty Geometry

4\\ Spyral Geometry

5\\ Shell Geometry

Time (Ultimaker 2)

13h 50mins

13h 26mins

12h 45mins

7h 44mins

7h 56mins

Time (Makerbot)

14h 14mins

13h 58mins

8h 1mins

8h 16mins

Volume

273 cm3

201 cm3

121 cm3

76 cm3

96 cm3

Quantity of material

14.54 m

11.55 m

12.75 m

7.59 m

9.64 m

115 gr

94 gr

110 gr

63 gr

71 gr

21.2 cm /34 cm

21.8cm /35 cm

23.7cm /38 cm

25cm /40cm

9/216

12/288

11/244

Weight

13h 11mins

Continuity

Dimensions

N of Pieces

18.7cm /30 cm

6/144

6/144

Studies and strategies to optimize time and material and maximize of dimensions 24 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.5 Optimization 1\\ Full Geometry

2\\ Cut Geometry Instance

Instance

Time (Ultimaker 2)

13h 50mins

13h 26mins

Time (Makerbot)

14h 14mins

13h 58mins

Volume

273 cm3

201 cm3

Quantity of material

14.54 m

11.55 m Geometry

Geometry

Weight

115 gr

94 gr

Continuity

Dimensions

18.7cm /30 cm

21.2 cm /34 cm

N of Pieces

6/144

6/144

Due to the long printing time a method to decrease print time and preserve the geometry’s form was essential. There are 5 methods of study which consider the full model, the cut model, the empty model, the spiral geometry and finally the shell geometry.

The criteria of comparison are print time (for both ultimaker and makerbot printers), volume of geometry, quantity of material, weight, continuity of geometry, dimensions, and number of printed pieces for each instance and the whole geometry.

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2.5 Optimization 3\\ Empty Geometry

4\\ Spyral Geometry

Instance

Time (Ultimaker 2)

12h 45mins

Time (Makerbot)

13h 11mins

8h 1mins

Volume

121 cm3

76 cm3

Quantity of material

12.75 m

Weight

Geometry

110 gr

7h 44mins

7.59 m

Instance

Geometry

63 gr

Continuity

Dimensions

21.8cm /35 cm

23.7cm /38 cm

N of Pieces

9/216

12/288

As the result, with both the cut and empty geometry, the print time does not decrease enough due to large amount of supports needed during the printing.

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The spirally cut geometry, on the contrary, reduces abundantly time, volume and material but the physical experiment prior to actualization was unsuccessful and it requires to be split into many segments with print angles lesser than 45째.

2.5 Optimization

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2.5 Optimization 5\\ Shell Geometry

Time (Ultimaker 2)

7h 56mins

Time (Makerbot)

8h 16mins

Volume

96 cm3

Quantity of material

9.64 m

Weight

Instance

Geometry

71 gr

Continuity

Dimensions

25cm /40cm

N of Pieces

11/244

The final attempt was to use the surface geometry in the form of a shell.

This produced similar feedbacks as the spiral geomety without the problem of having to print pieces at odd angles.

28 MANIFOLD ASSEMBLAGES | AADRL 2014 |

Furthermore this shell allows to orientate the pieces on the printer bed so that once the supports are removed the geometry mantains the external surface clean.

2.5 Optimization

Brushing

Blowing

Waxing

Complete Shell Geomtry printed in powder WAX. Compared to plastic the powder is very fragile.

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2.6 Volume constraints

build volume

desktop space

Ultimaker 2

C x 24

All the parts composing the geometry have to fit the volume corresponding to the build volume of the 3D printer. The resulting assembled geometry has to be as bigger as possible.

Pieces composing one instance : 11 Number of instances: 24 Pieces composing the whole geometry: 264

B x 24

A x 24 20.5 cm F x 24

E x 24

G x 24

D x 24 23.0cm

K x 24

J x 24 I x 24

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D x 24

22.5cm

2.6 Volume constraints

25 cm

25 cm

40 cm

Each edge of the single triangle measures 25 cm, the diametre of the assembled geometry measures 40 cm.

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2.7 Printer constraints MAKERBOOT SETTINGS

Time (Black Parts) Time (White Parts)

Travelling speed 150 Extruding Speed 90

Travelling speed 110 Extruding Speed 70

4h 20mins

4h 49mins

3h 50mins

4h 15mins

Fill Density: 10% Layer Height: 0.2 mm Supports: Touching buildplate and Brim

ULTIMAKER SETTINGS Travelling speed 150 Extruding Speed 90

Travelling speed 110 Extruding Speed 70

Time (Black Parts)

4h 19mins

4h 32mins

Time (White Parts)

3h 58mins

4h 12mins

Fill Density: 10% Layer Height: 0.2 mm Supports: Touching buildplate and Brim

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2.7 Printer constraints Surface Quality and Orientation White pieces were printed vertically so the quality of the external surfaces, that need to have the best finish, is good.

Black pieces were printed horizontally with the external faces looking up so the removed support structures are evident just in the internal side of the model.

Supports The “self-supporting” or “safe” zone from 135° to 45°, does not require any support to print the model. To reduce the support structures the pieces were printed as more vertical as possible. Some of the black parts where printed horizontally because they are quite flat.

Distance 0.3 mm between the different parts

Thickness 0.1 mm minimum wall thickness

Black Parts and White Parts composing one instance

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2.8 Shell geometry assemblage

Joint

Elements connection

34 MANIFOLD ASSEMBLAGES | AADRL 2014 |

2.8 Shell geometry assemblage

Assemblage for final shell model.

Due to the small thickness of the shell, the scale of the joints is extremely reduced and this causes a minor adherence between two pieces. For this reason all the connections were designed as more simple as possible.

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2.9 Scheme of assemblage

11 pieces composing 1 instance

B A

1\\

A/B/C white pieces D/E/F/G/H/I/J/K black pieces H

C I F

E

J

K

D H

2\\

G F

G

I

K J

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2.9 Scheme of assemblage C

3\\

4\\

B

C

5\\

6\\

7\\

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2.9 Scheme of assemblage

8\\

Once the triangles are assembled, it is possible to connect them together following the logic of connetions center to corner and opposite corner to center.

This allows to complete the entire geometry.

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9\\

2.9 Scheme of assemblage

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3\\ Virtual Geometry

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3.1 The spaces The geometry presents 3 space systems.

Since the geometry was cut into a shell-like structure, this generated the space within space (1-2) .

1\\ Space inside arms and elements

1 2

2\\ Void space in the center of the geometry

3\\ Space between external triangles and arms

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3

3.2 Nodes and connections For Unity 3D visualization the geometry was studied in terms of nodes and connections to amplify the possible paths of circulation inside the different elements.

3 connections from each Marginal Node to Central Nodes Central Nodes

Marginal Nodes

24 Central Nodes and 24 Marginal Nodes

3 connections from each Central Node to Marginal Nodes

72 total connections Hundreds of different possible paths

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3.3 Unity 3D

For Unity 3D visualization the shell was divided into two different materials, white outside and black inside. The surfaces removed from the original full geometry are here transparent, simulating glass.

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