Arch 410 Dig Fab Tool & Proc

ARCH 410 DIG FAB TOOL & PROC Fall 2024 Eryk Sysmans

1 MODULE 1 Vase pg 6 Infill pg 8 Gradient pg 12

2 MODULE 2

Tolerance Test pg 18 Modular Assembly pg 20

1

MODULE 1 Vase, Infill, & Gradient

1

VASE

Fig. 1

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VASE MODE PRINT

Fig. 2

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Fig. 3

DESCRIPTION VASE PRINTING

To create this case, we started off by creating six circles along one line in rhino. Then we manipulated five of these circles and lofted the shape. This create the organic form in the second image. After thats we capped this object exported it as an stl file to process in the 3D printing software. In ether bambu or Prusa we then loaded in this model from Rhino. One key thing to do is to set

the 3D printer setting to have vase on. This will tell the printer to only form a perimeter. This results in the tool path being created, as seen in the third image. Finally check the printing preview and ensure that there are no issues with the print.

Then load the g-code into a printer and print. The final result is seen in the last image.

1_ Rhino, line work 2_ Rhino, 3D Model 3_ Rhino, tool path 4_ Prusa, Print preview 5_ Picture, physical model

| ERYK SYSMANS

Fig. 4

1_ Rhino, line work 2_ Rhino, 3D Model 3_ Rhino, tool path 4_ Prusa, Print preview 5_ Picture, physical model

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Fig. 5

1

INFILL

Fig. 6

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INFILL PRINT

Fig. 7

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Fig. 8

DESCRIPTION INFILL PRINTING

This projects started off by created a curved line. Off set this line by a minimum of 3/8” as that is the minimum required distance for printer to infill. Next close off this shape and join the lines, then extrude the shape and create a wall.

After that export the stl into the prusa printer. The tool path of this object is seen in the third image, this allows you to preview the print.

Ensure that there are no printing issues highlighted by the print preview in prusa and then export the g code and load it into a Prusa.

The final product can be seen in the last image. One thing that was done to create an open top was in the print settings, this lay was taken off.

6_ Rhino, line work 7_ Rhino, 3D Model 8_ Rhino, tool path 9_ Prusa, Print preview 10_ Picture, physical model 11_ Rhino, exploded axon

| ERYK SYSMANS

Fig. 9

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Fig. 10

Infill Pattern

Inner Perimeter

Outer Perimeter 6_ Rhino, line work 7_ Rhino, 3D Model 8_ Rhino, tool path 9_ Prusa, Print preview 10_ Picture, physical model 11_ Rhino, exploded axon

Solid Infill Fig. 11

1

INFILL PATTERN

Fig. 12

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INFILL PRINT NO SHELL

Fig. 13

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Fig. 14

DESCRIPTION INFILL PATTERN

This project started off the same as the previous one, with a line and shape being created. This shape was then extruded and exported as an stl into the Prusa. However, where this project varied was in the print settings. In this set up the top and horizontal fill was tuned off. This mean that the infill would just be printed and not the shell. One thing to note is that to give the infill

something to attach to, I left the bottom piece on. This allowed for the print to be more structurally sound that just the infill being printed. After checking the preview and ensuring there are no print issues export the g-code. After printing the object should look like the last photo.

12_ Rhino, line work 13_ Rhino, 3D Model 14_ Rhino, tool path 15_ Prusa, Print preview 16_ Picture, physical model

| ERYK SYSMANS

Fig. 15

12_ Rhino, line work 13_ Rhino, 3D Model 14_ Rhino, tool path 15_ Prusa, Print preview 16_ Picture, physical model

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Fig. 16

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1

GRADIENT

Fig. 17

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GRADIENT PRINTING

Fig. 18

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Fig. 19

DESCRIPTION GRADIENT PRINT 1

This model started off by manipulating a grasshopper gradient script provided in class. I altered were the thickness of the voxels and the intensity of the gradient.

While this print was not printed on the Pursa and was printed on the fuse printer. This allowed for the structure of the model to not be as supported as it would be for the prusa model. If printed on the prusa

the model would need to no longer have any overhangs. Both types of prints would take a day to finish, however the fuse print was printing with the rest of the class.

17_ Rhino, gradient face 18_ Rhino, axon view 19_ Rhino, tool path of iteration 20_ Prusa, print preview 21_ Photo, 3D printed gradient model

| ERYK SYSMANS

Fig. 20

17_ Rhino, gradient face 18_ Rhino, axon view 19_ Rhino, tool path of iteration 20_ Prusa, print preview 21_ Photo, 3D printed gradient model

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Fig. 21

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1

GRADIENT

Fig. 22

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GRADIENT PRINTING

Fig. 23

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Fig. 24

DESCRIPTION GRADIENT PRINTING 2

This project ended up differently than the previous iteration. I made this one more simple due to the overhang and significant time it would have taken to print the previous iteration. I manipulated the same features of the grasshopper script in this model. As seen in figure 25 the print time in this iteration was only 3.5 hours compared to the almost 24 hour print time in the

previous one. If this print had to be redone, the speed of the prusa should be decreased to reduce the stringiness of the print.

22_ Rhino, gradient face 23_ Rhino, axon view 24_ Rhino, tool path of iteration 25_ Prusa, print preview 26_ Photo, 3D printed gradient model

| ERYK SYSMANS

Fig. 25

22_ Rhino, gradient face 23_ Rhino, axon view 24_ Rhino, tool path of iteration 25_ Prusa, print preview 26_ Photo, 3D printed gradient model

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Fig. 26

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2

MODULE 2 Tolerance Test & Modular Assembly

2

TOLERANCE

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TOLERANCE TEST

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Fig. 27

DESCRIPTION

Fig. 28

Fig. 29

TOLERANCE PRINT

This project started off by creating a rectangle and dividing it equally into three parts. After that create three squares and manipulate the center lines to create interlocking shapes.

Then offset those interlocking lines by 0.3 mm to create an acceptable tolerance so that once printing these shapes can properly connect.

After that using the curve boolean command in rhino create three

shapes. Next, extrude these shapes, as seen in figure 28 and export this to prusa. Once in prusa print the objects and it should look like figure 31. Some things to note in this project is that the angle for the slanted interlocking pieces could have been more steep to better connect.

27_ Rhino, process for creating the shape 28_ Rhino, extruded shape 29_ Rhino, tool path 30_ Prusa, Print Preview 31_ Photo, Physical Model 32_ Photo, Physical Model 33_ Photo, Physical Model

| ERYK SYSMANS

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Fig. 31

Fig. 30

Fig. 32

27_ Rhino, process for creating the shape 28_ Rhino, extruded shape 29_ Rhino, tool path 30_ Prusa, Print Preview 31_ Photo, Physical Model 32_ Photo, Physical Model 33_ Photo, Physical Model

Fig. 33

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2

ASSEMBLY

Fig. 34

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MODULAR ASSEMBLY

Fig. 35

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Fig. 36

DESCRIPTION PARTITION WALL

This project centers around using interlocking blocks to create a lattice partition wall. To start this project, I started with a rough outline of the shape I wanted and then rebuilt the curve to create even spacing. I then moved the curve up 1” and rotated by 60 degrees. After that I lofted the curves and caped the shape. This created the shape in figure 37.

However, as seen in figure 39 this shape did not work as there was a gap in the interlock. This led me to redo the loft and create the shape seen in figure 40. This shape did end up working and allowed me to create the full pattern that will be used to make up the partition wall.

34_ Rhino, Primary Shapes 35_ Rhino, Plan of modular pattern 36_ Rhino, Shape moved up 1” 37_ Rhino, Lofted iteration 1 38_ Rhino, Modular 1 39_ Photo, Test Model 40_ Rhino, Lofted iteration 2 41_ Rhino, Modular 2 42_ Rhino, Modular pattern

| ERYK SYSMANS

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Fig. 37

Fig. 38

Fig. 39

Fig. 40

Fig. 41

Fig. 42

34_ Rhino, Primary Shapes 35_ Rhino, Plan of modular pattern 36_ Rhino, Shape moved up 1” 37_ Rhino, Lofted iteration 1 38_ Rhino, Modular 1 39_ Photo, Test Model 40_ Rhino, Lofted iteration 2 41_ Rhino, Modular 2 42_ Rhino, Modular pattern

1

ASSEMBLY

Fig. 43

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MODULAR ASSEMBLY

Fig. 44

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Fig. 45

DESCRIPTION PARTITION WALL

For architectural scale model of the partition wall I chose 0.5” scale.

This model consists of the modular pattern stacked on top of each other arrayed in the x direction. The wall is 12’ by 18’. For the final printed model due to time constraints I added a platform for the wall to stand, however it did not need this in the end and would have been able to be supported if not there. The final

model is seen in figure 47. This final model printed well and was accurate to the elevation seen in figure 43.

43_ Diagram, Elevation of scale wall 44_ Rhino, Partition wall 45_ Rhino, Tool path 46_ Prusa, Print preview 47_ Photography, Half inch scale wall model

| ERYK SYSMANS

Fig. 46

43_ Diagram, Elevation of scale wall 44_ Rhino, Partition wall 45_ Rhino, Tool path 46_ Prusa, Print preview 47_ Photography, Half inch scale wall model

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Fig. 47

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2

ASSEMBLY

Fig. 48

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MODULAR ASSEMBLY

Fig. 49

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Fig. 50

DESCRIPTION PARTITION WALL

For the large scale 1:1 model each one of these pieces measures 4.3”x4,3”x4”. I added secondary interlocking pieces to reduce the degrees of freedom and help add to the stability of the model. During the printing process I encountered issues with the Prusa printing too fast and causing holes in the bottom layer. This was solved by reducing the printing speed down to 85%.

This solved the issue but increased the print time from over 16 hours to 19 hours. In total I printed three models to demonstrate how the interlocking model works. The final print interlocked well and generally worked.

48_ Rhino, Tool path preview 49_ Prusa, Print preview 50_ Photo, Print process 51_ Photo, Large model 52_ Photo, Large model standing

| ERYK SYSMANS

Fig. 51

48_ Rhino, Tool path preview 49_ Prusa, Print preview 50_ Photo, Print process 51_ Photo, Large model 52_ Photo, Large model standing

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Fig. 52

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