Digital Fabrication

ARCH 410 DIGITAL FABRICATION 3D PRINTS-FALL 2024 Vikram Barretto

1 MODULE 1 VASE: Pg 6-9

INFILL WALL: Pg 10-13 INFILL PATTERN: Pg 14-17 GRADIENT INFILL: Pg 18-21

2 MODULE 2

TOLERANCE TEST: Pg 24-31 MODULAR ASSEMBLIES: Pg 32-37

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MODULE 1 INTRO TO 3D PRINTING

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VASE

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VASE PRINTING

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VASE PRINT VASE DESIGN, METHODS & PROCESSES

The design concept of this vase stems from an array of 5 or more circles spaced across a vertical line (see Fig. 1 ). The diameters of each circle were then manipulated and then lofted to create an organic form as seen in Fig. 2. following this, the process to 3D print this was simple.

Export the file as an STL out of Rhino and bring that into the software Prusa or Bambu, to be sliced.

In the slicer itself, we adjutsed the print settings to have it print via “Spiral Vase” only. This ensures that the tool path of the printer only runs around the perimeter of the object, thus printing with no infill (Fig. 3).

The slicer then runs a G-code slicing simulation that may show any failures in printing and follows up with warnings and suggestions to improve. The G-code is then

exported and plugged into the machine. In this case, the vase was printed with the Bambu X1 Carbon printer was completed in around 30 minutes as compared to an hour or more for the Prusa Slicer runtime.

1_ Rhino, line work (curves) 2_ 3D model creation in Rhino 3_ Prusa tool path in Rhino 4_Model in Prusa Slicer (preview)

| VIKRAM BARRETTO

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1_ Rhino, line work (curves) 2_ 3D model creation in Rhino 3_ Prusa tool path in Rhino 4_Model in Prusa Slicer (preview)

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VASE

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VASE PRINTING

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| VIKRAM BARRETTO

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5_ Photography, physical model 6_ Photography, physical model 7_ Photography, physical model 8_ Prusa tool path simulation preview

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INFILL WALL

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INFILL WALL PRINTING

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WALL PRINT INFILL PRINTING DESIGN & PROCESSES

The design idea of this wall began as a series of points along a curve (polyline) in Rhino, which were then extruded to create a wall with some thickness (fig. 9). The wall was then exported as an STL, similar to the Vase, and then imported into the Prusa Slicer software. In Prusa, the model was scaled and further manipulated, with higher degree of wall curvature added along with

a layer of varying thickness throughout the wall. For this print, the wall had an infill of roughly 15%, which is standard. The pattern used was a 3D honeycomb infill pattern which is highlighted in the next segment.

9_ Rhino 3D model extrusion 10_ STL model, manipulated 11_ Prusa tool path in Rhino 12_ Photography, physical model 13_ Photography, physical model

| VIKRAM BARRETTO

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9_ Rhino 3D model extrusion 10_ STL model, manipulated 11_ Prusa tool path in Rhino 12_ Photography, physical model 13_ Photography, physical model

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INFILL WALL

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INFILL WALL PRINTING

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14_ Photography, physical model 15_ Photography, physical model 16_ Prusa tool path simulation preview 17_ Rhino, exploded axonometric highlighting print layers

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14_ Photography, physical model 15_ Photography, physical model 16_ Prusa tool path simulation preview 17_ Rhino, exploded axonometric highlighting print layers

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INFILL PATTERN PRINTING

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INFILL WITHOUT WALLS INFILL PATTERN PRINT METHODS & PROCESSES

Printing an infill-only structure with a 3D honeycomb pattern involves a series of adjustments from design through slicing. Starting in Rhino, the model is kept minimal, focusing on generating a robust 3D honeycomb In Prusa a 3D honeycomb pattern was selected followed by an adjustment to the infill percentage to optimize the pattern’s stability and aesthetic appeal.

Once the structure is complete, it’s exported as an STL file.

In PrusaSlicer, specific settings ensure that only the infill prints, without external perimeters. Setting the perimeter count to zero and disabling both top and bottom layers creates an infill-only model. the 3D Honeycomb pattern as the infill style further enhances the structural complexity, adding depth

and dimension. The infill density was chosen at 10% to balance between strength and filament usage, ensuring a visually striking honeycomb pattern without the need for outer walls. The sliced file generates G-code that, when sent to the printer, results in a freestanding 3D honeycomb structure, layer by layer, showcasing the intricate infill pattern.

18_ Rhino, infill toolpath 19_ Rhino, infill wall toolpath form 20_ Photography, physical model 21_ Photography, physical model

| VIKRAM BARRETTO

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18_ Rhino, infill toolpath 19_ Rhino, infill wall toolpath form 20_ Photography, physical model 21_ Photography, physical model

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INFILL PATTERN

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INFILL PATTERN PRINTING

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22_ Photography, physical model 23_ Photography, physical model 24_ Photography, physical model 25_ Prusa, toolpath simulation

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22_ Photography, physical model 23_ Photography, physical model 24_ Photography, physical model 25_ Prusa, toolpath simulation

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GRADIENT PATTERNS

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GRADIENT INFILL PATTERNS GRADIENT INFILL DESIGN, METHODS & PROCESSES

Creating a 3D-printed gradient infill involves several steps, starting with Rhino and Grasshopper for design and ending with PrusaSlicer for printing. In Rhino, the model is designed, then Grasshopper is used to create a gradient infill pattern, often with the help of plugins like Pufferfish or Weaverbird to generate complex geometric variations within the infill.

This gradient can be controlled by parameters like density, scale, or orientation, creating a smooth transition from dense to sparse fill. Once the pattern is finalized, it’s baked into Rhino to create a mesh, which can be exported as an STL file. In PrusaSlicer, the STL is imported, and settings are adjusted to match the model’s specific requirements, including any

additional layer or infill adjustments that the slicer offers. The file is then sliced, generating G-code ready for printing. Finally, the G-code is transferred to the 3D printer, which produces a physical model with the custom gradient infill pattern as designed.

26_ Rhino, Grasshopper, crystallion lattices line work 27_ 3D model creation in Rhino 28_ Prusa tool path in Rhino 29_Model in Prusa Slicer (preview)

| VIKRAM BARRETTO

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26_ Rhino, Grasshopper, crystallion lattices line work 27_ 3D model creation in Rhino 28_ Prusa tool path in Rhino 29_Model in Prusa Slicer (preview)

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GRADIENT INFILL

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GRADIENT PATTERNS

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30_ Photography, physical model 31_ Photography, physical model 32_ Photography, physical model 33_ Prusa tool path simulation preview

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30_ Photography, physical model 31_ Photography, physical model 32_ Photography, physical model 33_ Prusa tool path simulation preview

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MODULE 2 MODULAR ASSEMBLIES

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TOLERANCE TESTING

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TOLERANCE TESTING MODULAR TOLERANCE TEST METHODS & PROCESSES

This design was created using Rhino and Grasshopper to develop interlocking modular assemblies featuring hexagonal faces with nonplanar, topological contact surfaces.

The hexagonal geometry was selected for its structural stability and tessellation advantages, allowing seamless connections and efficient load distribution.

The overall form was intentionally designed to lean at an angle of 20 degrees, introducing a dynamic visual element while maintaining the structural capacity to hold and support the interlocking pieces securely.

The non-planar surfaces enhance friction and ensure the modules lock

firmly. Tolerances of 0.3mm were rigorously tested during prototyping to balance precision with ease of assembly. Designed parametrically, the geometry was iteratively refined for optimal fit and functionality before being prepared for 3D printing.

34_ 3D model creation in Rhino 35_ 3D model creation in Rhino 36_ 3D model creation in Rhino 37_Model in Prusa Slicer (preview) 38_ 3D printed model in Prusa Bed 39_ 3D printed model in Prusa Bed

| VIKRAM BARRETTO

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34_ 3D model creation in Rhino 35_ 3D model creation in Rhino 36_ 3D model creation in Rhino 37_Model in Prusa Slicer (preview) 38_ 3D printed model in Prusa Bed 39_ 3D printed model in Prusa Bed

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TOLERANCE TEST

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TOLERANCE TESTING

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MODULAR INTERLOCKING SYSTEM CONNECTION DESIGN, TESTING & PROCESSES

The modular assembly design evolved to enhance its structural capacity by increasing the depth of the modules, allowing them to support greater loads. This was achieved by creating more surface area contact between the interlocking pieces, improving their overall stability and durability. connection but also added a sense of dimension and complexity to

the structure. The increased depth not only strengthened the physical connection but also added a sense of dimension and complexity to the structure. Additionally, the flat hexagonal face was transformed into a subtly curved surface, introducing a dynamic, wavy effect that propagates throughout the assembly when the modules are connected.

This curvature adds visual interest and breaks the monotony of flat geometries, creating a more organic and fluid aesthetic. The wavy pattern also contributes to the structure’s ability to distribute loads evenly across its surface, enhancing its performance as an angled assembly while maintaining its interlocking functionality.

45_ 3D model creation in Rhino (Evolution) 46_ 3D model creation in Rhino (Evolution) 47_ 3D model creation in Rhino (Evolution) 48_Model in Prusa Slicer (preview) 49_Photography, physical model

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45_ 3D model creation in Rhino (Evolution) 46_ 3D model creation in Rhino (Evolution) 47_ 3D model creation in Rhino (Evolution) 48_Model in Prusa Slicer (preview) 49_Photography, physical model

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MODULAR ASSMEBLIES | 006 INTERLOCKING ASSEMBLY

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MODULAR INTERLOCKING SYSTEM MODULAR ARRANGMENT - 1/4” SCALE

This aggregation of the modules at an architectural scale is an example of the wall assembly of the modular design and its application. The modular design not only allows for ease of fabrication and assembly but also theoretically can be applied to other materials as well.

This is illustrated through the base and top modules, which are offcuts of each other, minimizing manufacturing costs and fabrication intensity in areas such as Timber or Metal.

This assembly can be used as an acoustical wall mock up or a display piece and possibly can be load bearing.

55_ 3D model creation in Rhino 56_ 3D model creation in Rhino 57_Model in Prusa Slicer (preview) 58_Photography, physical model

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55_ 3D model creation in Rhino 56_ 3D model creation in Rhino 57_Model in Prusa Slicer (preview) 58_Photography, physical model

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MODULAR ASSEMBLIES | 006 INTERLOCKING ASSEMBLY

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59_Photography, physical model 60_ Prusa tool path in Rhino 61_Photography, physical model 62_Photography, physical model

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59_Photography, physical model 60_ Prusa tool path in Rhino 61_Photography, physical model 62_Photography, physical model

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MODULAR INTERLOCKING SYSTEM

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TESTING LARGE ITERATIONS

At a larger scale, these modules are designed to interlock seamlessly, enabling the creation of alternative modular arrangements that are more rectilinear in form. This flexibility allows for the adaptation of the design into practical configurations, such as vertically or horizontally aligned systems, making them versatile for different uses.

Additionally, the offcuts from the

modules are purposefully designed to interlock as well, forming separate modules of entirely different forms. This efficient use of material not only minimizes waste but also introduces new design possibilities by creating complementary pieces. These secondary modules can be assembled into unique configurations, adding to the

system’s adaptability. The rectilinear arrangements and their offcut-derived counterparts can serve functional purposes, such as modular storage units. The interlocking approach enables easy assembly, disassembly, and reconfiguration, catering to various spatial and organizational needs while maintaining a cohesive aesthetic.

63_ Photography, physical model 64_ Photography, physical model 65_ Photography, physical model 66_ Photography, physical model

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