Thesis Book

2022

Riddharth

Ecem

Courses

802

Instructor:

TA:

804

Instructors:

AIRFORMATICS

Blow Formed FGD Additive Manufacturing for Lightweight

MSD-RAS 2024

Shenaia Turner

Riddharth Jain

Ecem Karaduman

2024 Spring Semester Project Book

Masters of Science in Design: Robotics & Autonomous Systems (MSD-RAS)

Weitzman School of Design, University of Pennsylvania

Students:

Shenaia Turner

Riddharth Jain

Ecem Karaduman

Courses contributing to this book:

802 Material Agencies: Robotics & Design Lab

Instructor: Robert Stuart-Smith

TA: Renhu “Franklin” Wu

804 Advanced RAS Programming Instructors: Jeffrey Anderson

806 Experimental Tooling Instructor: Nathan King

808:Scientific Research & Writing

Instructor: Billie Faircloth

MSD-RAS Program Director: Robert Stuart-Smith

Chair of Architecture: Rossana Hu

ARI Robotics Lab Manaager:

Nicholas Sideropoulos

Shunta Moriuchi

Special thanks to:

Advanced Research & Innovation Robotics Lab (ARI) Director: Winka Dubbeldam

MSD-RAS Fall instructors; Andrew Saunders, Alicia Nahmad Vazquez, Jeffrey Anderson, Emek Erdolu, Patrick Danahy.

Weitzman Senior Director of Operations & Planning: Karl Wellman

Dean of Weitzman School of Design: Fritz Steiner

Weitzman School Advisors & Donors who supported the construction of the ARI Robotics Lab

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AIRFORMATICS

Blow Formed FGD Additive Manufacturing for Lightweight

Architectural Components

Shenaia Turner, Riddharth Jain, Ecem Karaduman

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CONTENTS:

Introduction to Research

Chapter 1:

Glass Blowing & Blow Molding Methodologies

Chapter 2: FDM Printing

Chapter 3: Research Objectives, Questions, and Workfl ow

Research

Chapter 4: FDM Experiments - Wall Thickness & Ridges Parameters

Chapter 5: Initial Infl ation Workfl ow & Results

Chapter 6: Infl ation Simulation Workfl ow & Results Comparison

Chapter 7: FGD Experiments - Wall Thickness & Ridges Parameters

Chapter 8: Automated Infl ation

Chapter 9: Post-Processing Scanning and Milling

Chapter 10: Assembly

Chapter 11: Grid System & Full Scale Prototype

Chapter 12: Building Application - Overall Pavilion Proposal

APPENDIX

Acknowledgements

References

Our research relates to the artisanal and industrial processes of glass blowing and thermoplastic blow molding for pet bottles and similar materials.

Both processes commense with a small preform to become a larger object. While blow molding relies on a mold research has been undertaken into blow forming without molds from 3D printed preforms.

Glass Blowing

[1]

[2] Blow Molding

PneuFab Aera Fabrica

PneuFab lab’s research on inflated PLA preforms achieved a technique to alter the shape of a preform using pressure and heat. The project claimed that PLA can be inflated and heated beyond its glass temperature and less than its melting temperature, offering Airformatics an approach to inflate geometrically informed preforms that are FDM printed objects deducing the final form based on the preform.

Fillip Studios project Aera Fabrica experiments with inflating 3D printed PLA parts to explore aesthetic possibilities. They recognize the 3D-printed shape determines the final form removing the need for a mold. These experiments have utilized desktop filament based 3D printers and don’t offer an approach to larger scale fabrication and unsuitable for architectural applications.

[3]

[4]

Research Objectives

Develop a blow forming manufacturing process that utilizes industrial manufacturing for inflation of variably shaped preforms.

Research Questions

Could the inflation of thermoplastic preforms be a suitable manufacturing method to create thin-walled high volume architectural components?

What is the ideal preform shapes for controlled inflation formation?

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Ridges Geometry Tests with Rounded Bottoms and 2- 4 Ridges

Scalability of Inflation/Print Time

Scalability of Inflation/ Wall Thickness

Inflation Simulation Results

FDM Primitive & Ridges Bulbs Tests

Different Wall Thicknesses Effect to Inflated Geometry Layer Height

Preform Geometries with Different Ridges

Inflated Geometries with 2 Ridges

Inflated Geometries with 4 Ridges

Different Wall Thicknesses Effect to Inflated Geometry Layer Height

Steps to Robotic Inflation

To inflate thermoplastic modules, we used two methods. Manual inflation and robotically controlled automated inflation. Manual inflation was simply having the process done using hands, that is immersion in water, moving the preform to inflation space post heating and pressure control. Post realizing the immersion time, pressure requirements and inflation time for a given wall thickness, the above-mentioned procedures were done using UR-10 robot with a custom end effector. The initial inflation setup used one solenoid and regulator that were manually adjusted. The final inflation setup used one pressure supply split 4 separate ways allowing the automatic switching between different pressures merging back into one outlet connected to the preform. The solenoids are controlled using a set of buttons, that were connected to the corresponding solenoids using a relay through an Arduino setup. Each button, when pressed, would switch the pressure supply through the corresponding solenoid to command the pressure.

Exploded Axon Solenoid Box Setup

Set pressure range using regulators, initially set at 5, 10, 15, and 20 PSI respectively, housing all equipment in a confined moveable, mountable PLA housing.

1. UR-10 Robot

2. Heating Sheet

3. Turkey Pot

4. Inflation Space

5. Carbon fiber, UR-10 to Aluminum Section Connector

6. Aluminum Section 10 Series

7. Carbon fiber, Aluminum Section to Preform Connector

8. Carbon fiber, M-8 Screws

9. Preform

UR-10 robot with custom inflation end effector, consisting a 2 part setup- robot end and floor heating and inflation setup. This setup addresses to safety concerns with hot water and robotic arm movement.

Steps to Robotic Scanning

Steps to Robotic Milling

1/4” End Mill End Effector

Prototype aligns pieces along the seams made by ridges

Acknowledgements

This research was conducted through the Spring 2024 curriculum for the Master of Science in Design: Robotics and Autonomous Systems (MSD-RAS) Program in the Weitzman School of Design, University of Pennsylvania.

Thank you to the following instructors for their guidance provided in the respective courses:

• Billie Faircloth

• Jeffrey Anderson

• Nathan King

• Robert Stuart-Smith (MSD-RAS Program Director)

Scientific Research & Writing Advanced RAS Programming Experimental Tooling Material Agencies: Robotics & Design Lab

Thank you to Renhu “Franklin” Wu as TA.

Thank you to Nicholas Sideropoulos and Shunta Moriuchi for contributing to this work through your management of the ARI Robotics Lab.

Additional gratitude to the amazing staff at the University of Pennsylvania, specifically, Karl Wellman.

References

[1] Website

“CTGB_G12.” Evan Douglis Studio. Accessed May 14, 2024. https://www.evandouglis.com/ctgb-g12.

[2] Website

“Injection Blow Molding for Plastic Products & Parts: Berry Group.” Injection Blow Molding for Plastic Products & Parts | Berry Group. Accessed May 14, 2024. https://www.berryglobal.com/en/capabilities/manufacturing/blow-molding.

[3] Conference Paper

Wang, Guanyun, Kuangqi Zhu, Lingchuan Zhou, Mengyan Guo, Haotian Chen, Zihan Yan, Deying Pan, et al. “PneuFab: Designing Low-Cost 3D-Printed Inflatable Structures for Blow Molding Artifacts.” Proceedings of the 2023 CHI Conference on Human Factors in Computing Systems, April 19, 2023. https://doi.org/10.1145/3544548.3580923.

[4] Website

“Aera Fabrica.” Fillip Studios, June 15, 2022. https://www.fillipstudios.com/project/aera-fabrica/.