Optimizing Form & Material Behavior

Team member(s): Simon Amine, Ramziia Khairutdinova and Rafaela Müller
Modified by Simon Amine on November 1, 2022

Abstract

The aim of this exercise is the understanding of new production techniques through the relation between computer data and machine-oriented fabrication, bringing in a new perspective towards architecture and digital fabrication. As well as being able to invent strategies to translate geometry and systems into articulated and constructible solutions through exploring the opportunities arising from three digital fabrication processes: CNC Milling, Laser Cutting and 3D Printing.

CNC Milling

Modeling: Rhino + Grasshopper
CNC Machine: ShopBot
Materials: Plywood 30 mm
Post Processor: SBP
Workpiece Volume: 380x200x30 mm

CNC Milling Strategy (Total Mill time: 31 min)

RhinoCam Milling Diagram

Step 1: 2 Axis Profiling
Mill: Flat Mill
Flute: 2
Diameter: 6 mm
Spindle Speed: 12,000
Cut Direction: Mixed
Mill Time: 5 mins

Step 2: Horizontal Roughing
Mill: Flat Mill
Flute: 1
Diameter: 10 mm
Spindle Speed: 12,000
Cut Direction: Mixed
Step Down Control: 50%
Stepover Distance: 25
Mill Time: 6.4 mins

Step 3: Horizontal Roughing
Mill: Ball Mill
Flute: 2
Diameter: 6 mm
Spindle Speed: 12,000
Cut Direction: Mixed
Step Down Control: 25%
Stepover Distance: 3.175
Mill Time: 19.4 mins

Final Model Photographs

*Final Milled Workpiece Photograph 1, by Author*

*Final Milled Workpiece Photograph 2, by Author*

*Final Milled Workpiece Photograph 3, by Author*

Laser Cutting

Through laser cutting and folding technique, the aim was to join simple recycled timber beams to form complex spatial structures that follow a constructive assembly logic ruled by spatial joints. By having the main inspiration as origami folds, the module was designed in a matter that would offer multiple directions and angles of connection.

Modeling: Rhino + Grasshopper
Machine: R500
Materials: Cardboard – 5.7mm Double layered
Joint type: Folding

Laser Cutting Parameters
Cutting time: 6 mins / Module

Layer 1: Half Cut | Power 25 | Speed 2
Layer 2: Cut | Power 11 | Speed 2
Layer 3: Cut | Power 25 | Speed 2

Form / Surface

Timber Assembly

*Top View / Left View Joint Angles Diagrams*

Timber Connection Diagram

Module Aggregation

Module Aggregation Diagram

Final Model Photographs

*Laser Cutting Joint Photograph 1, by Author*

*Laser Cutting Joint Photograph 2, by Author*

*Laser Cutting Joint Photograph 3, by Author*

3D PRINTING

The aim of the design is to obtain a minimal surface having its openings’ direction and size controlled by attractor curves in order to optimize the sun and shading usage.