INTRODUCTION
Digital fabrication is the introductory course on manufacturing techniques explored by applying digital design into machine-oriented fabricatio
The aim of this course was to explore the design possibilities of Laser Cutting, CNC Milling and 3D Printing.
Through a three-week seminar we explored one machine per week, with enough time to prototype and produce the final model.
Each week we explored the strengths and weaknesses of each machine and produced design solutions accordingly.
CNC MILLING
Milled Tiles
Tutored fabrication with Shyam Francesco Zonca
The CNC Milling machine produces high accuracy parts from Rhino or CAD with a high level of automation.
As a subtractive manufacturing technology, the CNC cuts away pieces from a block. This can create complex 3D forms in relatively quick timeframes.
The exploration was restricted to a two hour slot and a hexagonal module of 360x180mm.
We developed a tile by exploring a voronoi structure that could have different heights, depths, and areas all through a grasshopper script. We imagined the script being tailored depending on weather and lighting needs for a facade.
CNC Milling strategies
Material: Plywood
Machine: Shopbot
Post Processor: Shopbot_MTC
Workpiece volume: 150x150x3mm
Horizontal Roughing
Flat Mill
Flute: 2
Diameter: 10mm
Spindle Speed: 12000
Cut Direction: Climb/ Conventional
Stepdown Control (dZ): 50%
Stepover Distance: 25%
Total mill time: 40.23 minutes
Horizontal Finishing
Ball Mill
Flute: 2
Diameter: – 6mm
Spindle Speed: 12000
Cut Direction: Climb/ Conventional
Stepover Control: 25%
Total mill time: 34.61 minutes??
Profiling
Flat Mill
Flute: 2
Diameter: 6mm
Spindle Speed: 12000
Cut Direction: Mixedl
Rough/ Depth Cut: 3mm
Total mill time: 4.96 minutes
3D PRINTING
Printed Tiles
Tutored by Ricardo Mayor
The 3D Printing Machine produces high accuracy parts from Rhino or CAD with a high level of automation.
As an additive manufacturing technology, the 3D printer allows for much more freedom in the forms it can create. Through the layering of filament the 3D printer can create complex forms although time consuming.
The exploration was restricted to a two hour slot and a hexagonal module of 360x180mm.
We developed a tile by exploring a voronoi structure that could have different heights, depths, and areas all through a grasshopper script. We imagined the script being tailored depending on weather and lighting needs for a facade.
Digital Process
- Curving and flower geometry
- Experimenting and creating a new perspective to spanish tiles
- Using light, 3D elements, and transparency to create a dynamic tile
Material: z-ABS
Technique: 3
Working Parameters: 0.29 Layer thickness & Rafted
Technique: Tile
Allotted Cutting time: 8hCutting time: 7h 10min
LASER CUTTING
Waffle Structure
Tutored fabrication with Ricardo Mayor Luque
Laser cutting is a technology that works by directing a high-power laser at materials,cutting them and leaving behind edges with a high-quality surface finish. Similar to CNC milling it is considered a subtractive technology, however it is restricted to just 2 axes. With that in mind, it relies on the discretization of complex shapes into flat developable surfaces and requires users to adapt their design strategies accordingly.
Our assignment was to design a spatial joint with different input angles while exploring different techniques such as interlocking, stacking, bending and in our case waffling. The goal for our design was to design an element which could be freely adapted to different situations through the use of parametric design principles and aided by the waffle structure’s rigidity.
Digital Process
- Double curve waffle joint
- Assembled by interlocking pieces
- Creates a structural interlocking waffle joint
- Allows for flexibility and modularity for timber elements
