Material-based design computation

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Architecture, 2010.Cataloged from PDF version of thesis.Includes bibliographical references (p. 306-328).The institutionalized separation between form, structure and material, deeply embedded in modernist design theory, paralleled by a methodological partitioning between modeling, analysis and fabrication, resulted in geometric-driven form generation. Such prioritization of form over material was carried into the development and design logic of CAD. Today, under the imperatives and growing recognition of the failures and environmental liabilities of this approach, modern design culture is experiencing a shift to material aware design. Inspired by Nature's strategies where form generation is driven by maximal performance with minimal resources through local material property variation, the research reviews, proposes and develops models and processes for a material-based approach in computationally enabled form-generation. Material-based Design Computation is developed and proposed as a set of computational strategies supporting the integration of form, material and structure by incorporating physical form-finding strategies with digital analysis and fabrication. In this approach, material precedes shape, and it is the structuring of material properties as a function of structural and environmental performance that generates design form. The thesis proposes a unique approach to computationally-enabled form-finding procedures, and experimentally investigates how such processes contribute to novel ways of creating, distributing and depositing material forms. Variable Property Design is investigated as a theoretical and technical framework by which to model, analyze and fabricate objects with graduated properties designed to correspond to multiple and continuously varied functional constraints. The following methods were developed as the enabling mechanisms of Material Computation: Tiling Behavior & Digital Anisotropy, Finite Element Synthesis, and Material Pixels. In order to implement this approach as a fabrication process, a novel fabrication technology, termed Variable Property Rapid Prototyping has been developed, designed and patented. Among the potential contributions is the achievement of a high degree of customization through material heterogeneity as compared to conventional design of components and assemblies. Experimental designs employing suggested theoretical and technical frameworks, methods and techniques are presented, discussed and demonstrated. They support product customization, rapid augmentation and variable property fabrication. Developed as approximations of natural formation processes, these design experiments demonstrate the contribution and the potential future of a new design and research field.by Neri Oxman.Ph.D

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

Material ecology

The world of design has been dominated since the Industrial Revolution by the rigors of manufacturing and mass production. Assembly lines have dictated a world made of standard parts framing the imagination of designers and builders who have been taught to think about their design objects and systems in terms of assemblies of parts with distinct functions. The assumption that parts are made of single material and fulfill predetermined specific functions is deeply rooted in design and usually goes unquestioned; it is also enforced by the way that industrial supply chains work. These age-old design paradigms have been reincarnated in Computer-aided Design (CAD) tools as well as Computer-aided Manufacturing (CAM) technologies where homogeneous materials are formed into pre-defined shapes at the service of pre-determined functions

Gemini: Engaging Experiential and Feature Scales Through Multimaterial Digital Design and Hybrid Additive–Subtractive Fabrication

Gemini is a chaise lounge constructed using hybrid fabrication involving 3D printing of a textured polymeric skin combined with CNC milling of a wooden chassis. The texture of the chaise was inspired by the seed geometry of the Ornithogalum dubium flower and designed using a computational implementation of an inhomogeneous Poisson process. The 3D-printed texture was informed by the weight distribution of a person with the goal of delivering structural support and comfort on the one hand and maximizing the absorption of sound emanating from exterior sources of noise on the other. Gemini is the first functional object produced using the Stratasys Objet500 Connex3 color multimaterial 3D printer including the Tango+ soft material. It represents one of the first cases of a hybrid additive–subtractive manufacturing approach, which combines the strength of both of these techniques

Methods and apparatus for additive manufacturing of glass

In illustrative implementations of this invention, a crucible kiln heats glass such that the glass becomes or remains molten. A nozzle extrudes the molten glass while one or more actuators actuate movements of the nozzle, a build platform or both. A computer controls these movements such that the extruded molten glass is selectively deposited to form a 3D glass object. The selective deposition of molten glass occurs inside an annealing kiln. The annealing kiln anneals the glass after it is extruded. In some cases, the actuators actuate the crucible kiln and nozzle to move in horizontal x, y directions and actuate the build platform to move in a z-direction. In some cases, fluid flows through a cavity or tubes adjacent to the nozzle tip, in order to cool the nozzle tip and thereby reduce the amount of glass that sticks to the nozzle tip

Making data matter: Voxel printing for the digital fabrication of data across scales and domains

We present a multimaterial voxel-printing method that enables the physical visualization of data sets commonly associated with scientific imaging. Leveraging voxel-based control of multimaterial three-dimensional (3D) printing, our method enables additive manufacturing of discontinuous data types such as point cloud data, curve and graph data, image-based data, and volumetric data. By converting data sets into dithered material deposition descriptions, through modifications to rasterization processes, we demonstrate that data sets frequently visualized on screen can be converted into physical, materially heterogeneous objects. Our approach alleviates the need to postprocess data sets to boundary representations, preventing alteration of data and loss of information in the produced physicalizations. Therefore, it bridges the gap between digital information representation and physical material composition. We evaluate the visual characteristics and features of our method, assess its relevance and applicability in the production of physical visualizations, and detail the conversion of data sets for multimaterial 3D printing. We conclude with exemplary 3D-printed data sets produced by our method pointing toward potential applications across scales, disciplines, and problem domains

Grown, Printed, and Biologically Augmented: An Additively Manufactured Microfluidic Wearable, Functionally Templated for Synthetic Microbes

Despite significant advances in synthetic biology at industrial scales, digital fabrication challenges have, to date, precluded its implementation at the product scale. We present, Mushtari, a multimaterial 3D printed fluidic wearable designed to culture microbial communities. Thereby we introduce a computational design environment for additive manufacturing of geometrically complex and materially heterogeneous fluidic channels. We demonstrate how controlled variation of geometrical and optical properties at high spatial resolution can be achieved through a combination of computational growth modeling and multimaterial bitmap printing. Furthermore, we present the implementation, characterization, and evaluation of support methods for creating product-scale fluidics. Finally, we explore the cytotoxicity of 3D printed materials in culture studies with the model microorganisms, Escherichia coli and Bacillus subtilis. The results point toward design possibilities that lie at the intersection of computational design, additive manufacturing, and synthetic biology, with the ultimate goal of imparting biological functionality to 3D printed products.National Science Foundation (U.S.) (DGE1144152)United States. Department of Energy (DE-SC0012658

Additive Manufacturing of Optically Transparent Glass

We present a fully functional material extrusion printer for optically transparent glass. The printer is composed of scalable modular elements able to operate at the high temperatures required to process glass from a molten state to an annealed product. We demonstrate a process enabling the construction of 3D parts as described by computer-aided design models. Processing parameters such as temperature, which control glass viscosity, and flow rate, layer height, and feed rate can thus be adjusted to tailor printing to the desired component, its shape, and its properties. We explored, defined, and hard-coded geometric constraints and coiling patterns as well as the integration of various colors into the current controllable process, contributing to a new design and manufacturing space. We report on performed characterization of the printed materials executed to determine their morphological, mechanical, and optical properties. Printed parts demonstrated strong adhesion between layers and satisfying optical clarity. This molten glass 3D printer demonstrates the production of parts that are highly repeatable, enable light transmission, and resemble the visual and mechanical performance of glass constructs that are conventionally obtained. Utilizing the optical nature of glass, complex caustic patterns were created by projecting light through the printed objects. The 3D-printed glass objects described here can thus be extended to implementations across scales and functional domains including product and architectural design. This research lies at the intersection of design, engineering, science, and art, representing a highly interdisciplinary approach.Massachusetts Institute of Technology. Department of Mechanical EngineeringGlass Art Society (Technology Advancing Glass Grant

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)