Beyond developable: computational design and fabrication with auxetic materials

We present a computational method for interactive 3D design and rationalization of surfaces via auxetic materials, i.e., flat flexible material that can stretch uniformly up to a certain extent. A key motivation for studying such material is that one can approximate doubly-curved surfaces (such as the sphere) using only flat pieces, making it attractive for fabrication. We physically realize surfaces by introducing cuts into approximately inextensible material such as sheet metal, plastic, or leather. The cutting pattern is modeled as a regular triangular linkage that yields hexagonal openings of spatially-varying radius when stretched. In the same way that isometry is fundamental to modeling developable surfaces, we leverage conformal geometry to understand auxetic design. In particular, we compute a global conformal map with bounded scale factor to initialize an otherwise intractable non-linear optimization. We demonstrate that this global approach can handle non-trivial topology and non-local dependencies inherent in auxetic material. Design studies and physical prototypes are used to illustrate a wide range of possible applications

IST Austria Thesis

Fabrication of curved shells plays an important role in modern design, industry, and science. Among their remarkable properties are, for example, aesthetics of organic shapes, ability to evenly distribute loads, or efficient flow separation. They find applications across vast length scales ranging from sky-scraper architecture to microscopic devices. But, at the same time, the design of curved shells and their manufacturing process pose a variety of challenges. In this thesis, they are addressed from several perspectives. In particular, this thesis presents approaches based on the transformation of initially flat sheets into the target curved surfaces. This involves problems of interactive design of shells with nontrivial mechanical constraints, inverse design of complex structural materials, and data-driven modeling of delicate and time-dependent physical properties. At the same time, two newly-developed self-morphing mechanisms targeting flat-to-curved transformation are presented. In architecture, doubly curved surfaces can be realized as cold bent glass panelizations. Originally flat glass panels are bent into frames and remain stressed. This is a cost-efficient fabrication approach compared to hot bending, when glass panels are shaped plastically. However such constructions are prone to breaking during bending, and it is highly nontrivial to navigate the design space, keeping the panels fabricable and aesthetically pleasing at the same time. We introduce an interactive design system for cold bent glass façades, while previously even offline optimization for such scenarios has not been sufficiently developed. Our method is based on a deep learning approach providing quick and high precision estimation of glass panel shape and stress while handling the shape multimodality. Fabrication of smaller objects of scales below 1 m, can also greatly benefit from shaping originally flat sheets. In this respect, we designed new self-morphing shell mechanisms transforming from an initial flat state to a doubly curved state with high precision and detail. Our so-called CurveUps demonstrate the encodement of the geometric information into the shell. Furthermore, we explored the frontiers of programmable materials and showed how temporal information can additionally be encoded into a flat shell. This allows prescribing deformation sequences for doubly curved surfaces and, thus, facilitates self-collision avoidance enabling complex shapes and functionalities otherwise impossible. Both of these methods include inverse design tools keeping the user in the design loop

From Folds to Structures, a Review

International audienceStarting from simple notions of paper folding, a review of current challenges regarding folds and structures is presented. A special focus is dedicated to folded tessellations which are raising interest from the scientific community. Finally, the different mechanical modeling of folded structures are investigated. This reveals efficient applications of folding concepts in the design of structures

Interactive design exploration for constrained meshes

In architectural design, surface shapes are commonly subject to geometric constraints imposed by material, fabrication or assembly. Rationalization algorithms can convert a freeform design into a form feasible for production, but often require design modifications that might not comply with the design intent. In addition, they only offer limited support for exploring alternative feasible shapes, due to the high complexity of the optimization algorithm. We address these shortcomings and present a computational framework for interactive shape exploration of discrete geometric structures in the context of freeform architectural design. Our method is formulated as a mesh optimization subject to shape constraints. Our formulation can enforce soft constraints and hard constraints at the same time, and handles equality constraints and inequality constraints in a unified way. We propose a novel numerical solver that splits the optimization into a sequence of simple subproblems that can be solved efficiently and accurately. Based on this algorithm, we develop a system that allows the user to explore designs satisfying geometric constraints. Our system offers full control over the exploration process, by providing direct access to the specification of the design space. At the same time, the complexity of the underlying optimization is hidden from the user, who communicates with the system through intuitive interfaces

Dev2PQ: Planar Quadrilateral Strip Remeshing of Developable Surfaces

We introduce an algorithm to remesh triangle meshes representing developable surfaces to planar quad dominant meshes. The output of our algorithm consists of planar quadrilateral (PQ) strips that are aligned to principal curvature directions and closely approximate the curved parts of the input developable, and planar polygons representing the flat parts of the input. Developable PQ-strip meshes are useful in many areas of shape modeling, thanks to the simplicity of fabrication from flat sheet material. Unfortunately, they are difficult to model due to their restrictive combinatorics and locking issues. Other representations of developable surfaces, such as arbitrary triangle or quad meshes, are more suitable for interactive freeform modeling, but generally have non-planar faces or are not aligned to principal curvatures. Our method leverages the modeling flexibility of non-ruling based representations of developable surfaces, while still obtaining developable, curvature aligned PQ-strip meshes. Our algorithm optimizes for a scalar function on the input mesh, such that its level sets are extrinsically straight and align well to the locally estimated ruling directions. The condition that guarantees straight level sets is nonlinear of high order and numerically difficult to enforce in a straightforward manner. We devise an alternating optimization method that makes our problem tractable and practical to compute. Our method works automatically on any developable input, including multiple patches and curved folds, without explicit domain decomposition. We demonstrate the effectiveness of our approach on a variety of developable surfaces and show how our remeshing can be used alongside handle based interactive freeform modeling of developable shapes

String-Actuated Curved Folded Surfaces

Curved folded surfaces, given their ability to produce elegant freeform shapes by folding flat sheets etched with curved creases, hold a special place in computational Origami. Artists and designers have proposed a wide variety of different fold patterns to create a range of interesting surfaces. The creative process, design, as well as fabrication is usually only concerned with the static surface that emerges once folding has completed. Folding such patterns, however, is difficult as multiple creases have to be folded simultaneously to obtain a properly folded target shape. We introduce string actuated curved folded surfaces that can be shaped by pulling a network of strings, thus, vastly simplifying the process of creating such surfaces and making the folding motion an integral part of the design. Technically, we solve the problem of which surface points to string together and how to actuate them by locally expressing a desired folding path in the space of isometric shape deformations in terms of novel string actuation modes. We demonstrate the validity of our approach by computing string actuation networks for a range of well-known crease patterns and testing their effectiveness on physical prototypes. All the examples in this article can be downloaded for personal use from http://geometry.cs.ucl.ac.uk/projects/2017/string-actuated/

Holistic simulation of optical systems

For many years, the design of optical systems mainly comprised a linear arrangement of plane or spherical components, such as lenses, mirrors or prisms, and a geometric-optical description by ray tracing lead to an accurate and satisfactory result. Today, many modern optical systems found in a variety of different industrial and scientific applications, deviate from this structure. Polarization, diffraction and coherence, or material interactions, such as volume or surface scattering, need to be included when reasonable performance predictions are required. Furthermore, manufacturing and alignment aspects must be considered in the design and simulation of optical systems to ensure that their impact is not damaging to the overall purpose of the corresponding setup. Another important part is the growing field of digital optics. Signal processing algorithms have become an indispensable part of many systems, whereby an almost unlimited number of current and potential applications exists. Since these algorithms are an essential part of the system, their compatibility and impact on the completed system is an important aspect to con- sider. In principle, this list of relevant topics and examples can be further expanded to an almost unlimited extend. However, the simulation and optimization of the single sub-aspects do often not lead to a satisfactory result. The goal of this thesis is to demonstrate that the performance prediction of modern optical systems benefits significantly from an aggregation of the individual models and technological aspects. Present concepts are further enhanced by the development and analysis of new approaches and algorithms, leading to a more holistic description and simulation of complex setups as a whole. The long-term objective of this work is a comprehensive virtual and rapid prototyping. From an industrial perspective, this would reduce the risk, time and costs associated with the development of an optical system

ACM Transactions on Graphics

We present a computational approach for designing CurveUps, curvy shells that form from an initially flat state. They consist of small rigid tiles that are tightly held together by two pre-stretched elastic sheets attached to them. Our method allows the realization of smooth, doubly curved surfaces that can be fabricated as a flat piece. Once released, the restoring forces of the pre-stretched sheets support the object to take shape in 3D. CurveUps are structurally stable in their target configuration. The design process starts with a target surface. Our method generates a tile layout in 2D and optimizes the distribution, shape, and attachment areas of the tiles to obtain a configuration that is fabricable and in which the curved up state closely matches the target. Our approach is based on an efficient approximate model and a local optimization strategy for an otherwise intractable nonlinear optimization problem. We demonstrate the effectiveness of our approach for a wide range of shapes, all realized as physical prototypes