Water-Based Robotic Fabrication: Large-Scale Additive Manufacturing of Functionally Graded Hydrogel Composites via Multichamber Extrusion

Additive manufacturing (AM) of regenerated biomaterials is in its infancy despite the urgent need for alternatives to fuel-based products and in spite of the exceptional mechanical properties, availability, and biodegradability associated with water-based natural polymers. This study presents water-based robotic fabrication as a design approach and enabling technology for AM of biodegradable hydrogel composites. Our research focuses on the combination of expanding the dimensions of the fabrication envelope, developing structural materials for additive deposition, incorporating material-property gradients, and manufacturing architectural-scale biodegradable systems. This work presents a robotically controlled AM system to produce biodegradable-composite objects combining natural hydrogels, such as chitosan and sodium alginate, with other organic aggregates. It demonstrates the approach by designing, building, and evaluating the mechanics and controls of a multichamber extrusion system. Finally, it provides evidence of large-scale composite objects fabricated by our technology that display graded properties and feature sizes ranging from micro- to macroscale. Fabricated objects may be chemically stabilized or dissolved in water and recycled within minutes. Applications include the fabrication of fully recyclable products or temporary architectural components such as tent structures with graded mechanical and optical properties. Proposed applications demonstrate environmental capabilities such as water-storing structures, hydration-induced shape forming, and product disintegration over time.Massachusetts Institute of Technology. Media Laboratory (Mediated Matter research group)Massachusetts Institute of Technology. Department of Mechanical engineering (Additive Manufacturing (2.S998), Spring 2014

Flow-based fabrication: An integrated computational workflow for design and digital additive manufacturing of multifunctional heterogeneously structured objects

Structural hierarchy and material organization in design are traditionally achieved by combining discrete homogeneous parts into functional assemblies where the shape or surface is the determining factor in achieving function. In contrast, biological structures express higher levels of functionality on a finer scale through volumetric cellular constructs that are heterogeneous and complex. Despite recent advancements in additive manufacturing of functionally graded materials, the limitations associated with computational design and digital fabrication of heterogeneous materials and structures frame and limit further progress. Conventional computer-aided design tools typically contain geometric and topologic data of virtual constructs, but lack robust means to integrate material composition properties within virtual models. We present a seamless computational workflow for the design and direct digital fabrication of multi-material and multi-scale structured objects. The workflow encodes for and integrates domain-specific meta-data relating to local, regional and global feature resolution of heterogeneous material organizations. We focus on water-based materials and demonstrate our approach by additively manufacturing diverse constructs associating shape-informing variable flow rates and material properties to mesh-free geometric primitives. The proposed workflow enables virtual-to-physical control of constructs where structural, mechanical and optical gradients are achieved through a seamless design-to-fabrication tool with localized control. An enabling technology combining a robotic arm and a multi-syringe multi nozzle deposition system is presented. Proposed methodology is implemented and full-scale demonstrations are included

Driving macro-scale transformations in three-dimensional-printed biopolymers through controlled induction of molecular anisotropy at the nanoscale

Motivated by the need to harness the properties of renewable and biodegradable polymers for the design and manufacturing of multi-scale structures with complex geometries, we have employed our additive manufacturing platform that leverages molecular self-assembly for the production of metre-scale structures characterized by complex geometries and heterogeneous material composition. As a precursor material, we used chitosan, a chemically modified form of chitin, an abundant and sustainable structural polysaccharide. We demonstrate the ability to control concentration-dependent crystallization as well as the induction of the preferred orientation of the polymer chains through the combination of extrusion-based robotic fabrication and directional toolpathing. Anisotropy is demonstrated and assessed through high-resolution micro-X-ray diffraction in conjunction with finite element simulations. Using this approach, we can leverage controlled and user-defined small-scale propagation of residual stresses to induce large-scale folding of the resulting structures

MetaMesh: A hierarchical computational model for design and fabrication of biomimetic armored surfaces

Many exoskeletons exhibit multifunctional performance by combining protection from rigid ceramic components with flexibility through articulated interfaces. Structure-to-function relationships of these natural bioarmors have been studied extensively, and initial development of structural (load-bearing) bioinspired armor materials, most often nacre-mimetic laminated composites, has been conducted. However, the translation of segmented and articulated armor to bioinspired surfaces and applications requires new computational constructs. We propose a novel hierarchical computational model, MetaMesh, that adapts a segmented fish scale armor system to fit complex “host surfaces”. We define a “host” surface as the overall geometrical form on top of which the scale units are computed. MetaMesh operates in three levels of resolution: (i) locally—to construct unit geometries based on shape parameters of scales as identified and characterized in the Polypterus senegalus exoskeleton, (ii) regionally—to encode articulated connection guides that adapt units with their neighbors according to directional schema in the mesh, and (iii) globally—to generatively extend the unit assembly over arbitrarily curved surfaces through global mesh optimization using a functional coefficient gradient. Simulation results provide the basis for further physiological and kinetic development. This study provides a methodology for the generation of biomimetic protective surfaces using segmented, articulated components that maintain mobility alongside full body coverage.Massachusetts Institute of Technology. Institute for Soldier Nanotechnologies (Contract No. W911NF-13-D-0001)United States. Army Research Office (Institute for Collaborative Biotechnologies (ICB), contract no. W911NF-09-D-0001)United States. Department of Defense (National Security Science and Engineering Faculty Fellowship Program (Grant No. N00244-09-1-0064)

FIM

Thesis: Ph. D., Massachusetts Institute of Technology, School of Architecture and Planning, Program in Media Arts and Sciences, 2019Cataloged from PDF version of thesis.Includes bibliographical references (pages 188-200).This thesis discusses novel strategies to include physical media information at multiple dimensions and relating to diverse disciplines within traditional design tools. Specifically, it addresses challenges that arise when aiming at describing computational and manufacturing strategies for material-, time- and scale-dependent phenomena. Fabrication Information Modeling (FIM) develops design processes and exemplar projects able to operate across media, disciplines, and scales, incorporating concepts of multidimensionality, media-informed computation, and trans-disciplinary data integration. Digital fabrication is today a rapidly evolving concept transitioning from traditional assembly of differentiated parts, to file-to-fabrication construction efforts, and even towards guidance of material synthesis on-the-fly and growth of biological agents into structures. Advances in the fields of materials engineering, robotic automation, artificial intelligence, and synthetic biology open up opportunities for incorporating new physical world information, from organism, material, machine, and environment, within and throughout digital design and manufacturing processes. With FIM and FIM-driven projects I aim to contribute to the field of digital design and fabrication by enabling feedback workflows where (1) materials are designed rather than selected; where (2) the question of how information is passed across spatiotemporal scales is central to design generation itself; where (3) modeling at each level of resolution and representation relates traditionally-unlinked methods and is carried out by myriad media; and finally, where (4) virtual and physical considerations coexist as equals.by Jorge Duro Royo.Ph. D.Ph.D. Massachusetts Institute of Technology, School of Architecture and Planning, Program in Media Arts and Science

Workflow and methods for multi-scale trans-disciplinary informed design

Thesis: S.M., Massachusetts Institute of Technology, School of Architecture and Planning, Program in Media Arts and Sciences, 2015.Cataloged from PDF version of thesis.Includes bibliographical references (pages 67-70).This thesis sets the stage for Fabrication Information Modeling (FIM); a design approach for enabling seamless design-to-production workflows that can derive complex designs fusing advanced digital design technologies associated with analysis, engineering and manufacturing. Present day digital fabrication platforms enable the design and construction of high-resolution and complex material distribution structures. However, virtual-to-physical workflows and their associated software environments are yet to incorporate such capabilities. As preliminary methods towards FIM I have developed four computational strategies for the design and digital construction of custom systems. These methods are presented in this thesis in the context of specific design challenges and include a biologically driven fiber construction algorithm; an anatomically driven shell-to-wearable translation protocol; an environmentally-driven swarm printing system; and a manufacturing-driven hierarchical fabrication platform. I discuss and analyze these four challenges in terms of their capabilities to integrate design across media, disciplines and scales through the concepts of multidimensionality, media-informed computation and trans-disciplinary data in advanced digital design workflows. With FIM I aim to contribute to the field of digital design and fabrication by enabling feedback workflows where materials are designed rather than selected; where the question of how information is passed across spatiotemporal scales is central to design generation itself; where modeling at each level of resolution and representation is based on various methods and carried out by various media or agents within a single environment; and finally, where virtual and physical considerations coexist as equals.by Jorge Duro Royo.S.M

Towards Fabrication Information Modeling (FIM): Four Case Models to Derive Designs informed by Multi-Scale Trans-Disciplinary Data

Despite recent advancements in digital fabrication and manufacturing, limitations associated with computational tools are preventing further progress in the design of non-standard architectures. This paper sets the stage for a new theoretical framework and an applied approach for the design and fabrication of geometrically and materially complex functional designs coined Fabrication Information Modeling (FIM). We demonstrate systems designed to integrate form generation, digital fabrication, and material computation starting from the physical and arriving at the virtual environment. The paper reviews four computational strategies for the design of custom systems through multi-scale trans-disciplinary data, which are classified and ordered by the level of overlap between the modeling media and the fabrication media: (1) the first model takes as input biological data and outputs 3D printed digital materials organized according to functional constraints; (2) the second model takes as input geometry and environmental data and outputs robotically wound fibers organized according to functional constraints; (3) the third model takes as input material and environmental data and outputs CNC deposited pastes organized according to functional constraints; (4) the forth model takes as input biological, material and environmental data and outputs robotically deposited polymers organized according to functional constraints. The analysis of these models will demonstrate the FIM approach and point towards its value to designers who seek to inform their work through multi-scale transdisciplinary data, a capability that is currently missing from standard design-to-fabrication workflows.Massachusetts Institute of Technology. Institute for Soldier Nanotechnologies (Contract W911NF-13-D-0001)United States. Army Research Office. Institute for Collaborative Biotechnologies (Grant W911NF-09-D-0001)United States. Dept. of Energy. National Security Science and Engineering Faculty Fellowship Program (Grant N00244-09-1-0064)TBA-21 Academ

Parametric chemistry reverse engineering biomaterial composites for additive manufacturing of bio-cement structures across scales

Motivated by the need to develop novel renewable and biocompatible composites for complex macro-scale structures, and inspired by natural shell, insect cuticles, and plant cell walls, we have developed a multi-material, robotic 3D printing platform and associated computational techniques that leverage the concepts of parametric chemistry and tunable hierarchical structuring for the additive manufacturing of hierarchical biomaterials, in meter-scale forms, with complex geometries. To do so, we have designed and engineered a bio-cement composite using natural and abundant polymers such as chitosan and cellulose. After assessing the chemical, mechanical, and optical properties of this prototypical bio-composite, we utilized these results as inputs to modulate our computational design and robotic fabrication platforms. Doing so has taken us closer to our goal of true Fabrication Information Modelling (FIM), which integrates atomistic material properties to inform large-scale digital fabrication

Sequential Multimaterial Additive Manufacturing of Functionally Graded Biopolymer Composites

© Copyright 2020, Mary Ann Liebert, Inc., publishers 2020. Cellulose, chitin, and pectin are three of the most abundant natural materials on Earth. Despite this, large-scale additive manufacturing with these biopolymers is used only in limited applications and frequently relies on extensive refinement processes or plastic additives. We present novel developments in a digital fabrication and design approach for multimaterial three-dimensional printing of biopolymers. Specifically, our computational and digital fabrication workflow-sequential multimaterial additive manufacturing-enables the construction of biopolymer composites with continuously graded transitional zones using only a single extruder. We apply this method to fabricate structures on length scales ranging from millimeters to meters. Transitional regions between materials created using these methods demonstrated comparable mechanical properties with homogenous mixtures of the same composition. We present a computational workflow and physical system support a novel and flexible form of multimaterial additive manufacturing with a diverse array of potential applications