Digital Fabrication Research Articles

Unveiling interactions among architectural sketching, parametric design, and digital fabrication using linkography

ABSTRACT A design environment represents the context and ecosystem in which design activities are conducted. Today, architectural practice includes a range of design environments, including parametric design, CAM, and digital fabrication, in addition to sketch environments, which serve to ideate and manufacture the architectural entity. However, there is a lack of empirical studies that unveil interactions among these environments. Therefore, this article aims to answer the following question: What is the role of the design environments and the cognitive impact of the interactive dialog between the design environments on design productivity while considering the parametric design and digital fabrication as an integrated process? For this purpose, an empirical study comprising 11 architects with a minimum three years/projects of Grasshopper experience was conducted. Design tasks required a transition between sketch, parametric design and digital fabrication environments. Methodologically, data were obtained by concurrent and thinking-aloud methods, and the design process was analyzed using the linkograph method. The findings indicate that the synthesis process is more pronounced during the sketching phase and diminishes during the parametric design phase because of the cognitive gaps. On the other hand, the parametric design environment is observed as a supportive representational environment for recalling previous design actions.

Digital Workflow Optimization for Endocrown Restorations on Root- Treated Teeth

Endocrown restorations have become a popular solution for endodontically treated teeth, offering both functional and esthetic benefits. These restorations are particularly effective for molars due to the larger surface area of the pulp chamber, which enhances retention and stability. This article presents a clinical case of a zirconia endocrown restoration for a highly damaged mandibular molar. Utilizing a fully digital workflow, the preparation, design, and fabrication of the restoration were performed with precision, ensuring minimal tooth structure removal. Zirconia was chosen for its superior mechanical properties, including fracture resistance and durability. The challenges associated with zirconia, such as bonding reliability, were addressed through surface treatments like air abrasion and the use of 10-MDP-based chemical promoters. The patient’s outcome was both esthetically pleasing and functionally successful. This case highlights the advantages of integrating digital workflows and advanced materials in modern prosthodontic practice, while also acknowledging the need for careful selection of materials and techniques based on the individual case.

A scoping review of digital fabrication techniques applied to prosthetics & orthotics: Part 2 of 2—orthotics

Introduction: Traditionally, orthosis manufacturing is time and labor-intensive. Digitalization of some of the fabrication process is already ubiquitous, yet extension across device types could reduce the burden of manual labor and advance automation to help unblock access to assistive technologies globally. It seems, however, that appropriately strong evidence is holding this back. This review looks to thoroughly examine the current state of evidence to make this clear. Objectives: To identify gaps in the literature that create barriers to decision-making on either appropriate uptake by clinical teams or setting research directions, by identifying what forms of evidence the current research literature provides to the orthotics community. Study design: Scoping literature review. Methods: A comprehensive search was completed in the following databases: AMED, MEDLINE, EMBASE, Global Health Archive, CINAHL Plus, Cochrane Library, Web of Science, ACM, IEEE, and Engineering Village, resulting in 3487 articles to be screened. Results: After screening, 121 lower limb orthosis, 104 upper limb orthosis, and 30 spinal orthosis articles were included in this review. For some areas such as CAD/CAM-produced insoles and spinal orthoses, the evidence base is strong. For most additive manufacture articles, long-term, larger-scale studies as well as research into training requirements are lacking. Conclusion: The advantages of digital fabrication technology that could streamline orthotic device production in many cases are still blocked by a lack of strong formal evidence, ie large longitudinal studies with a range of evaluation measures. Increased collaboration between clinicians, patient/service users, academia, and industry could be a route to addressing these gaps and creating a better pathway to market for new technologies.

Multi-objective optimization framework based on review of form-finding of architectural parametric forms

Parametric architecture has played a vital role in architectural design in recent times. Research on early form-finding of architectural forms represents a notable area of study. Despite the significance of energy performance, digital fabrication, and aesthetics as design objectives, there is a lack of a comprehensive framework that integrates them in the form-finding process. To address this gap, this research conducts a systematic review of previous studies on form-finding and optimization of architectural forms, focusing on the three aforementioned objectives. Then, based on the analysis of the selected studies, the research proposes a multi-objective optimization framework for form-finding of architectural parametric forms, considering energy performance, digital fabrication, and aesthetics. The framework comprises five phases: form generation, multi-objective optimization, aesthetic evaluation, geometry rationalization, and digital fabrication of a prototype. This framework is usable by any architect, regardless of their programming knowledge, and is applicable to any new architectural design.

Application of Universal Design for Learning and Digital Fabrication in the Creation of a Tool for Inclusive Teaching of the Ordering of Chemical Elements

Application of Universal Design for Learning and Digital Fabrication in the Creation of a Tool for Inclusive Teaching of the Ordering of Chemical Elements

Innovative hybrid approach: digital and analog fabrication of orbital prosthesis for post-COVID-19 mucormycosis defects using photogrammetry technique

In addition to anatomical loss, removal of the full or portion of the orbit results in a facial deformity and psychological distress for the patient. This article details a practical case of prosthetic rehabilitation using digital workflow for an orbital deformity caused by post-COVID-19 Mucor mycosis. The main goal of this case study was to create a maxillofacial orbital prosthesis that is well-retained, simple to use, and accurate in terms of appearance. The study addresses the problems involved in fabricating the orbital prosthesis, particularly the unique dimensions and form of the defect, replicating the natural skin tone, and accomplishing retention by the most prudent and patient-friendly approach. Through this article, a digitised algorithm, using photogrammetry technique for facial scan, is suggested for fabricating the prosthesis.

D5 digital circular workflow: five digital steps towards matchmaking for material reuse in construction

The intersection of digital transformation and circular construction practices presents significant potential to mitigate environmental impacts through optimised material reuse. We propose a five-step (D5) digital circular workflow that integrates these digital innovations towards reuse, validated through real-world case studies. We assessed a variety of digital tools for enhancing the reuse of construction materials, including digital product passports, material classification assisted by artificial intelligence (AI), reality capture, computational design, design inspired by generative AI, digital fabrication techniques, extended reality, and blockchain technology. Using action research through a multiple case study approach, we disassembled several buildings that were set for demolition and subsequently designed and executed construction projects using the salvaged materials. Our findings indicate that digital transformation for detection, disassembly, distribution, design, and finally deployment significantly support the application of circular economy principles. We demonstrate the potential of the proposed workflow for industry implementation and scalability.

A Novel Triad of Bio-Inspired Design, Digital Fabrication, and Bio-Derived Materials for Personalised Bone Repair.

The emerging paradigm of personalised bone repair embodies a transformative triad comprising bio-inspired design, digital fabrication, and the exploration of innovative materials. The increasing average age of the population, alongside the rising incidence of fractures associated with age-related conditions such as osteoporosis, necessitates the development of customised, efficient, and minimally invasive treatment modalities as alternatives to conventional methods (e.g., autografts, allografts, Ilizarov distraction, and bone fixators) typically employed to promote bone regeneration. A promising innovative technique involves the use of cellularised scaffolds incorporating mesenchymal stem cells (MSCs). The selection of materials-ranging from metals and ceramics to synthetic or natural bio-derived polymers-combined with a design inspired by natural sources (including bone, corals, algae, shells, silk, and plants) facilitates the replication of geometries, architectures, porosities, biodegradation capabilities, and mechanical properties conducive to physiological bone regeneration. To mimic internal structures and geometries for construct customisation, scaffolds can be designed using Computer-aided Design (CAD) and fabricated via 3D-printing techniques. This approach not only enables precise control over external shapes and internal architectures but also accommodates the use of diverse materials that improve biological performance and provide economic advantages. Finally, advanced numerical models are employed to simulate, analyse, and optimise the complex processes involved in personalised bone regeneration, with computational predictions validated against experimental data and in vivo studies to ascertain the model's ability to predict the recovery of bone shape and function.

Research on the method of digital technology assisted direct resin composite restoration for deep distal caries in mandibular second molars

Objective: To explore the digital design and fabrication technology of personalized restorative matrix for dental filling, and to explore the feasibility of direct resin restoration for deep caries lesions in distal neck of mandibular second molar. Methods: For patients with deep caries lesions in the distal neck of the mandibular second molar who visited the Department of Cariology and Endodontology of Peking University School and Hospital of Stomatology from September 2023 to April 2024, after preparing the cavity and gingival retractor, a three-dimensional intraoral scanner was used to obtain three-dimensional data of the patient's dentition. In the dental restoration computer-aided design software, the inlay function was used to generate the restored tooth morphology. The edge range of the personalized restorative matrix was drawn on the restored model by three-dimensional reverse engineering software to achieve edge sealing effect. The selected edge range data was processed with distal shelling to generate a digital model of a personalized restorative matrix with a thickness of 0.5 mm. A metal three-dimensional printer was used to fabricate the titanium alloy restorative matrix, and its application was completed in 10 clinical cases. The marginal adaptation and retention stability of the personalized restorative matrix were evaluated under a dental microscope, and forming effect evaluation was performed through immediate postoperative periapical radiographs. Results: The preliminary clinical application of the personalized restorative matrix fabricated using digital technology revealed that, in the treatment of 10 affected teeth, rubber dam isolation was successfully ensured, resulting in clinically effective direct resin composite restorations with optimal marginal adaptation and reasonable contours. Immediate postoperative periapical radiographs showed good convexity of the filling body, with no overhangs found. Both marginal adaptation and retention stability met the requirements of clinical treatment. Conclusions: The personalized restorative matrix designed in this study can solve the clinical problems of moisture separation and resin forming in the treatment of deep caries lesions in distal neck of the mandibular second molar, and can achieve stable and reliable adhesive restoration effects.

Fostering technical skills and creativity in the digital fabrication spaces: an open-ended prototyping approach

AbstractThis paper explores the impact of a digital fabrication course on the development of digital fabrication skills and creativity. The course focused on open-ended prototyping and aimed to investigate its effects on students’ motivation, enjoyment, and confidence. Students’ creativity levels were measured using a creativity test at the beginning and end of a seven-week course. Additionally, the students shared their subjective feedback on their skills and experiences in designing and fabricating prototypes using digital fabrication tools. The results showed that prototyping activities significantly improved students’ overall creativity and perceived proficiency in 2D and 3D modeling, prototyping, embedded programming, and operating fabrication machines. Students’ confidence increased across most skills, although some of their motivation and enjoyment for certain skills decreased by the end of the course. It was also revealed that collaborative learning was perceived as enjoyable and not always suitable for developing certain personal skills, such as 2D modelling and programming. Future research could investigate pedagogical approaches tailored to individual needs and collaborative configurations for optimal skill development.

Cooperative augmented assembly (CAA): augmented reality for on-site cooperative robotic fabrication

Recent years have witnessed significant advances in computational design and robotic fabrication for large-scale manufacturing. Although these advances have enhanced the speed, precision, and reproducibility of digital fabrication processes, they often lack adaptability and fail to integrate manual actions in a digital model. Addressing this challenge, the present study introduces cooperative augmented assembly (CAA), a phone-based mobile Augmented Reality (AR) application that facilitates cooperative assembly of complex timber structures between humans and robots. CAA enables augmented manual assembly, intuitive robot control and supervision, and task sharing between humans and robots, creating an adaptive digital fabrication process. To allocate tasks to manual or robotic actions, the mobile AR application allows multiple users to access a shared digital workspace. This is achieved through a flexible communication system that allows numerous users and robots to cooperate seamlessly. By harnessing a cloud-based augmented reality system in combination with an adaptive digital model, CAA aims to better incorporate human actions in robotic fabrication setups, facilitating human–machine cooperation workflows and establishing a highly intuitive, adaptable digital fabrication process within the Architecture, Engineering, and Construction sector.

AI Meets Distributed Manufacturing: Wie KI die Verbreitung digitaler Fertigung fördert

Abstract These often use computer-controlled machines like 3D printers and CNC machines. The accessibility of these technologies is increasing, even for non-experts. This leads to widespread use and democratisation of manufacturing technologies, which can support distributed urban production. We present recent developments of an AI-supported laser cutter based on Open Source Hardware (OSH). Our approach integrates machine learning methods, including diffusion-based image generation and Large Language Models. This enables seamless integration of CAD-CAM systems. By combining hands-on learning with OSH machines and digital tools, we ensure a better understanding of the manufacturing workflow. We demonstrate the capability, accessibility, and potential of our approach using OSH machines. This can significantly influence future developments in digital fabrication.

THE FUTURE OF 3D PRINTING IN MANUFACTURING (INNOVATIVE TECHNOLOGY REVOLUTIONIZING MANUFACTURING PROCESSES AND PRODUCTS)

"Imagine a world where you can create anything you want just by pressing a button! That's the magic of 3D printing. In the future, this technology will change how we make things in big factories. Instead of traditional methods, like cutting and molding, 3D printers use special materials to build layer by layer. It's like building with Legos, but in real life! This cool technology lets us make custom toys, tools, and even houses. It's like having a superpower to create whatever we can imagine. Scientists are even exploring using 3D printing to make body parts and yummy food! With 3D printing, we can reduce waste and make things more efficiently. It's like a glimpse into the future where creativity knows no bounds. So, get ready to witness the amazing world of 3D printing!" KEYWORDS 3D Printing, Additive Manufacturing, Customization, Sustainability, Bioprinting, Material Innovation, Industry 4.0, Supply Chain, Prototyping, Regulatory Compliance, Automation, Innovative Design, Waste Reduction, Manufacturing Efficiency, Digital Fabrication, Creative Empowerment.

A piezoresistive dielectric elastomer switch consisting of inkjet-printed carbon black

The piezoresistive effect is a key physical property utilized in soft and stretchable electronics, functioning as intrinsic electromechanical sensors. However, most conventional piezoresistive sensors can only passively measure and quantify external stimuli. To address these limitations, this work integrates an inkjet-printed piezoresistive pattern and a dielectric elastomer actuator (DEA) into a single monolithic dielectric elastomer film, creating a dielectric elastomer switch (DES). This DES can realize dramatic resistance changes along with DEA actuation, leveraging DEA-driven piezoresistivity for active and effective circuit control and signal processing. Theoretically, the DES operates by exhibiting resistance change through the periodic compression induced by DEA actuation. Experimentally, the piezoresistive pattern and the DEA electrodes were fabricated on an acrylic dielectric elastomer (VHB) using inkjet-printed piezoresistive carbon black (CB) and manually brushed conductive grease, respectively. The optimized DES demonstrated approximately 3.77 (±0.11) orders of magnitude in resistance change at a DEA frequency of 0.1 Hz. Compared to previously reported methods (smearing and stamping), inkjet-printed CB patterns showed significant improvements. These included negligible Joule heating impact, precise digital fabrication control, larger resistance change (up to 3.77 orders of magnitude), faster response speeds to DEA actuation (∼0.25 s for 3 orders of magnitude in resistance change), and greater durability (operating at 0.5 Hz for 112 min). Scanning electron microscopy (SEM) characterization revealed that these improvements were attributed to a more uniform distribution of conductive “CB islands” and appropriate non-conductive gap size among them. For demonstrating the applications of DES, it was employed for LED control, DEA-based soft gripper control, and as a multiplexer for signal processing.

3D PRINTING WITH NATURAL MATERIALS IN CIVIL CONSTRUCTION

The construction industry has experienced a number of transformations due to the use of digitalization and automation. Additive manufacturing, also known as 3D printing, is a current example. The purpose of this paper is to analyze the use of natural materials based on soil applied to 3D printing technology, with a focus on the thermal performance of buildings. A exploratory literature review was used to identify applied research that has explored these materials. The data obtained was systematized in a comparative table to identify the main strategies used. The analysis of applied research indicates that construction using 3D printing with materials based on soil is promising, taking advantage of the soil's natural thermal insulation properties and being able to incorporate parametric design and digital fabrication strategies to create complex, customized solutions for different contexts.

INTEGRATION OF DIGITAL FABRICATION LABORATORIES AND COMPUTATIONAL DESIGN INTO THE ARCHITECTURE CURRICULUM IN TÜRKİYE

The discipline of architecture undergoes transformation practically, cognitively, and pedagogically due to the widespread use of digital design and fabrication technologies in design processes. This paper aims to eluctade the integration of digital fabrication and computational design with architectural design education at undergraduate level. For this purpose, this study examined the undergraduate course contents and spatial conditions of leading universities with digital fabrication laboratories under three headings: digital design, digital fabrication, and spatial reflections. In addition, this research applied semi-structured interviews with the relevant faculty members of three universities that have robotic tools to obtain more detailed information about their pedagogical approaches. According to this study, the curriculum and laboratories are rapidly changing. As a result, architecture departments are expanding their facilities by building laboratories and tools that have the potential for architectural education to fill the gap between practice and theory. However, there are economic limitations to implementing digital fabrication technologies in terms of the tools and materials used by hundreds of students. This research discusses the requirements, potentials, and limitations of theoretical and practical training through digital fabrication tools that should be included in these courses in the curriculum.

Teachers as reflective learning experience designers: Bringing design thinking into school-based design and maker education

School-based design and maker education foster the acquisition of 21st-century competencies.Teachers play a crucial role in integrating explorative design thinking and digital fabrication into schools; however, gaps remain in designing, implementing, and reflecting on these processes. This research positions teachers as reflective designers of learning experiences.The case study outlines key elements of learning design and explores the implementation of a project tailored for 13-14-year-old students. A thematic, theory- and data-driven analysis examined the challenges and opportunities in the teacher’s and researcher-teacher’s (Noora, the first author) in-situ and post-reflections on pedagogical practices and the teacher’s role. Three intertwined themes emerged: design leader, collaboration and co-teaching, and (co-)reflection. Through (co-)reflections, they structured and led the design process while simultaneously developing their professional skills. The article also advocates for the necessary mindset and skillset of teachers, emphasizing the importance of professional development and collaboration in enhancing the quality of school-based design and maker education. These insights can guide the application and evolution of existing frameworks to assist teachers, researchers, and other facilitators in introducing creative, hands-on learning experiences into formal education.

Obturator Innovations for Individuals Post-Hemimaxillectomy: Confronting Challenges

Hemimaxillectomy patients frequently experience difficulties in speech, swallowing, and overall quality of life due to the loss of anatomical structure and function. Advancements in obturator design and materials enhance fit, retention, and comfort, as well as innovations in digital fabrication techniques that allow for customized solutions tailored to individual anatomical needs. Common challenges faced by patients, including issues related to adaptation, psychosocial impact, and the importance of interdisciplinary care, are addressed. Through case studies and recent research findings, effective strategies for optimizing obturator functionality and improving patient outcomes are highlighted. This review aims to provide insights into the evolving landscape of prosthetic rehabilitation for hemimaxillectomy patients, highlighting the importance of ongoing innovation in enhancing their quality of life. It explores the latest advancements in obturator systems tailored for individuals who have undergone hemimaxillectomy, a procedure that leads to significant functional and aesthetic challenges.

An investigation of prototype development using 3D printer: A digital fabrication approach

Abstract Additive manufacturing (AM) is a widely used technique in several industries for rapid prototyping and layer-by-layer fabrication of a new product. The influence of printer settings and print quality is essential for the performance of products in a variety of applications. The popularity of manufacturing using 3D printing is growing rapidly. In view of this, an investigation is carried out on the 3D printing techniques, their applications, and prototype materials for complex mechanical parts such as an impeller. The present study thoroughly considers the fundamental techniques in 3D printing technology, materials, and recent advancements applied to the current application and accepted trends. The 3D printing technology is advantageous as it accepts a wide range of designs, allows customized manufacturing, minimizes waste, builds intricate structures, and creates prototypes rapidly. Layer height of 0.2 mm, speed of 90 mm/s, and infill density of 80% were determined as the optimal print settings considering time, material cost, and properties. Considering the flexural qualities, the optimized values of layer height, print speed, and infill density were 0.15 mm, 70 mm/s, and 50%, respectively. It was observed that the uniform elongation (UEL) and ultimate stress (UTS) of a component increase as the layer thickness increases for the considered layers.

Computational Design with Kurtboğaz: The Generation of Timber Structures with an Aggregative Design Algorithm

This paper investigates the form-finding capacity of the traditional timber-joint construction method, Kurtboğaz, aiming to explore new architectural forms and possibilities through computational design techniques to preserve vernacular construction methods and integrate them into contemporary architecture. It presents an Aggregative Design Algorithm (ADA) that creates different structures based on designer rules and simple assembly rules of Kurtboğaz, leading to unique emergent forms through random rule application. The paper also explores how reinforcement learning, a type of machine learning, can improve this design process through a theoretical framework. The study tries to use a rule-based generative algorithm to explore the modular and reconfigurable characteristics of the Kurtboğaz. The ADA enables random rule application, leading to diverse forms. However, several challenges may be encountered during the application of ADA because of its random aggregation, such as collision avoidance, structural integrity, boundary detection, and the optimization of structural parameters. The study suggests using Reinforcement Learning (RL) in the ADA framework to address these problems. Incorporating RL is anticipated to enable the algorithm to adaptively learn and optimize the form-finding process, enhancing the performance and applicability of the Kurtboğaz method in contemporary architectural practice. In the future, with this generative process described by the study, designs that create spatial differences with the help of walls, floors, and rooms on a human scale can be realized. The study also plans to explore the synergy between craftsmanship and digital fabrication in the future