Digital Fabrication Portfolio.2023-2024

Zahra Cheragh Nia Digital Fabrication Portfolio 2023-2024

I am a computational designer with a background in architecture and experience in digital fabrication, additive manufacturing, and robotic fabrication.

Utilizing advanced design and fabrication techniques, I develop innovative solutions for a wide range of projects.

Zahra.Cheraghnia@mail.polimi.it

Table of Content

01

Additive Manufacturing

02

Graph-Based Mesh Panelization

03

Incremental Sheet Forming

04

Pick & Place

05

Soft Robotic Solar Facade

3D Printing Plastic and Clay

CNC Cut - Augmented Reality

Robotic Fabrication

Robotic Assembly

Soft Pneumatic Actuators

- 01 Additive Manufacturing 3D Printing Plastic and Clay SMAC Summer School Supervisor: Stefano Giovacchini Software: Rhino - Grasshopper

During this summer school, we delved into additive manufacturing using both clay and plastic, exploring their possibilities, limitations, and various applications. I developed two projects—one for clay and one for plastic— that initially followed the same concept. However, after evaluating the unique characteristics and limitations of each material, I made specific modifications to adapt the designs. Both systems were developed with the potential to function as facade systems or integral components of one.

Plastic

Designed Geometry

Contouring

Process Simulation Tool Path planes

Tool Path Creation

Calibrating the End Effector

Program Simulation

Vision for the Future

Clay

Pattern variations

Parametric Pattern Algorithm

- 02 Graph-Based Mesh Panelization CNC Cut - Augmented Reality Final Project - IndexLab Supervisor: Pierpaolo Ruttico Software: Rhino - Grasshopper

This project explores advanced fabrication methods for complex shading elements on building facades, integrating algorithmic programming, robotics, and augmented reality (AR). By developing a digital workflow that unifies design, fabrication, and performance analysis, the research demonstrates how robotic fabrication and AR can enhance precision, efficiency, and sustainability.

Through a case study, the project shows that these technologies streamline the design-to-fabrication process and improve the adaptability and performance of architectural facades, laying the groundwork for future innovation in complex architectural systems.

1. Base Surface

2. Rationalization

3. Offsetting

4. Clustering

5. Panelization

6. Optimization to Find Maximized Stiffness and Overlap Between the Two Layers

1.Folding Lines of the panels

2.Rivet connection Between Layers

3.Final connected module

Connections

2.Panel Labelling

1.Base Panel Labelling

4.Angle Labelling

3.Surface Labelling

1.Outline of the Panel

2.Rivet Holes

Documentation

Setting Up Augmented Reality Using Fologram

3.Fold Lines

4. Documentation

Off site Module Assembly Back Layer Panels 10 x 10 cm steel profile

Connecting Rivets Front Layer Panels

Facade to screen connection System

Off site assembled module

Assembled view

M6 Hilti Bolted Connection

Steel profile for locking module

Steel profile for locking module

Steel profile for locking module

10 x 10 cm Vertival stud steel profile

D

D

10.05

D

99.00

00

80.00

80.00

100.05

150.

00

10.05

150.

2.00 150.00

10.00

100.00

D5.00

80.00

80.00

D5.00

D5.00

On-site Assembly

145.00

D5.00

10.00

Assembled Side view

2.50

2.50 30.00

30.00 60.00

80.00

150.00

M6 Hilti Bolted steel T- Profile Connection with Connection vertical stud

- 03 Incremental Sheet Forming Robotic Fabrication Final Project - IndexLab Supervisor: Pierpaolo Ruttico Software: Rhino - Grasshopper

This project explores advanced fabrication methods for complex shading elements on building facades, integrating algorithmic programming, robotics, and augmented reality (AR). By developing a digital workflow that unifies design, fabrication, and performance analysis, the research demonstrates how robotic fabrication and AR can enhance precision, efficiency, and sustainability.

Through a case study, the project shows that these technologies streamline the design-to-fabrication process and improve the adaptability and performance of architectural facades, laying the groundwork for future innovation in complex architectural systems.

Tool Path Generation

Initial Geometry

Incorporating Small Planar Surfaces

Rationalization

Typology 1

Typology 2

Identifying the Different Curvatures

Tweening through the boundary curves

Second Set of Toolpath

1. Starting Point ABB IRB 4600-45/2.05

2. Incrementing Process

3.Final Point

Process Simulation

On-site Assembly

Fixture System Assembly

End Effector Assembly

Calibration Process

- 04 Pick & Place Robotic Assembly

Robotic Programming - RWTH University Instructors: Ethan Kerber Software: Rhino - Grasshopper - KUKA|prc Introduction to Robotic Programming” course by RWTH Aachen University offers a foundational overview of key concepts in robotics, focusing on kinematics, dynamics, and control systems. Through this course, I gained essential skills in robotic programming, learning how to effectively manage and control robot movement using tools like ROS (Robot Operating System).

The course emphasized practical application, allowing me to apply theoretical knowledge to real-world scenarios. By the end of the course, I developed a strong understanding of robotic principles and honed my ability to program and control robotic systems, preparing me for more advanced work in the field of robotics.

Start Position PTP Pick up Approach Position

Open Gripper

LIN Pick up Position

Open Gripper

LIN Pick up Retract Position PTP

Pick Up

Assembly Approach Position LIN Open Gripper

Assembly Position LIN Assembly Retract Position PTP End Position

Assembly

Pick up

Transition

Assembly

Return Home

- 05 Soft Robotic Solar Facade Soft Pneumatic Actuators

Adaptive Facade Studio - IndexLab Supervisor: Pierpaolo Ruttico Software: Rhino - Grasshopper Solymorph is an integrated kinematic building facade designed to optimize energetic behavior and architectural expression through individual modules.

Installed on an existing library facade at Politecnico di Milano, Lecco, this case study demonstrates significant improvements in electricity generation compared to static photovoltaic systems.

The project highlights the potential for energy savings in various climates and aims to drive advancements in sustainable building design by leveraging soft robotics and artificial intelligence. This innovative approach contributes to developing energy-efficient facade solutions for both new constructions and existing buildings.

System Breakdown 0. Existing building façade

1. Main steel frame

2. Steel anchor rods

3. Cable net structure

4. Soft robot assembly

5. Hexagonal PV-panels

Surface Generation

Supporting Frame

Edge Anchors

Cable Structure

Solar Panels

Soft Robots at Nodes

Structural Analysis

Solar Radiattion Analysis

Cable Connection To The Building

1. Existing Structure I-Beam 2.Main Support Beam Heb160 3. L-Section 150x12 Top Sliding Beam 4. Module Steel Frame Hss 160x80x5 5. Rollers 6. Steel Rod Od73 7. U-Section 150x80 Bottom Sliding Beam

Connection to The Structure

Node Assembly

Soft Robot Unit Assembly

1. Support rod node 73mm with 3 20mmø holes

1. 10mm thick, 100mm long steel support legs

2. 20mm thick 242mmø steel connecting ring node 73mmø

2. 2mm thick aluminum universal joint with aluminium plate

internal diameter

3. Silicon actuator

4. Steel connector

3. Steel no hub coupling 73 mmø

5. Junction box

6. 1mm aluminum sheet

4. Cable connector

a)The arrangement of combined cables at a central point

5. Combined cable

7. Hexagonal PV panel

b) ø250mm aluminum disc supported by the OD73 steel rod suspended from the frame

c) Aluminum cantilever

Silicon Actuator

Silicon Actuator Rotation

18mm Hollow Chamber for Cables

10mm Thick Silicon Top 2mm Thick Al Universal Joint to Stabilize The Actuator And Restrict Z-Axis Movement Silicon Actuator with 3mm Thick Valve

Universal Joint

10mm Thick Silicon Base

Designed Mold for the Physical Prototype

Zahra Cheragh Nia Zahra.cheraghnia@mail.polimi.it 2023-2024