Digital Fabrication Research Articles

Digital light processing fabrication of porous cordierite ceramics from polysilxoane-based slurries

Herein, a pohotosentive polysiloxane (PSO)/talc/Al2O3 slurry was prepared for the digital light processing printing. Liquid photosensitive PSO was exploited as a triple-functioned material, acting both as the resin matrix, a high reactive Si source and a pore generator. Through adjusting the raw material components, polysiloxane can be sintered with talc and Al2O3 fillers after being pyrolyzed to 1200 oC while pores with variable diameters can be generated. Ternary component slurry prepared based on the above strategy possesses the characteristics of low viscosity, high reaction activity and good homogeneity. Sintering schedule of the printed thin-walled precursor was investigated to guarantee the morphology of cordierite product was consistent with the printed model. This work aims to provide a new strategy for DLP printing of MgO-Al2O3-SiO2 ternary and other polymer derived ceramics.

Integrative Structural Design of Nonstandard Building Systems: Bridging the Gap Between Research and Industry

The utilization in architecture of computational design and digital fabrication, coupled with the exploration of new material systems, brings the potential to break with conventional ways of building. However, these emerging nonstandard structures also demand new ways of designing and proving the structure’s integrity and safety. This paper aims to develop an integrative structural design methodology and workflow to design, optimize, and validate nonstandard building systems by combining a multiscale and digital-physical approach. The methods are showcased with coreless filament winding (CFW) structures, an additive manufacturing method representative of nonstandard building systems made possible by robotic fabrication. The results demonstrate the potential of this methodology to shorten the gap between research and industry, facilitating the realization of innovative structures.

Recent developments towards digital concrete

Concrete formulation, despite recent progress, remains challenging due to the increasing number of constituents and performance requirements. This study explores a parallel approach to physical and semi-empirical experimental proportioning methods, utilizing machine learning (ML) or deep learning (DL). By harnessing big data from concrete production and high throughput experimentation, ML/DL algorithms can optimize mixes, minimizing waste and maximizing performance. This approach, combined with digital fabrication, addresses environmental and productivity concerns in construction. However, challenges such as diverse non-digital experimental methods, lack of basic data on waste streams, and limited open repositories on cement-based materials hinder the widespread use of data-driven techniques. This paper examines the background and potential of data-driven techniques in the field of concrete technology.

Effect of the structuration rate on dimensional stability and mechanical performance of 3D printed mortars

Digital concrete fabrication is a novel construction technique in which structural elements are built layer by layer without the use of formwork. This technology has introduced new challenges in materials engineering. More emphasis lies on the structuration behavior of cement-based materials. Concrete is designed to achieve adapted workability to flow during the pumping phase. It also requires proper build-up and stiffness to retain its shape after extrusion and sustain its own weight and, subsequently, the weight of successive layers. A high degree of structuration is recommended to ensure high printing quality. However, this may adversely affect the performance of the multi-layer printing process. In the present study, an experimental program was carried out to evaluate the impact of structuration rate on the dimensional stability and mechanical properties of the printed element at both early age and long term, respectively. Four different mixtures with various structuration rates were designed and printed. In the fresh state, variations in the layer’s height and width were recorded to evaluate the dimensional stability of the printed structure. On the other hand, several specimens were cut out of the freshly printed elements for mechanical tests. The compression and flexural tests were conducted after 7 and 28 days of moist-curing. The obtained results showed that there exists an optimum rate of structuration above which the quality of the bonding interface is compromised, generating losses in mechanical properties. Under this threshold, anisotropic behavior dominates, leading to low dimensional stability.

From Logo Programming to Fab Labs: The Legacy of Constructionist Learning in K−12 Education Technology

Mens et manus, the motto that is embedded in the MIT official seal, is a simple Latin phrase that translates to “mind and hand.” As a continuation of MIT’s pioneering education and research, Seymour Papert, a renowned educator and learning theorist, established the foundation of constructionism, which emphasizes hands-on/minds-on learning. This article explores the evolution of constructionism in K-12 educational technology from the Logo computer language to Scratch block-based programming and the introduction of Fab Labs, which represent the third-generation platform for constructionist teaching and learning. The use of Fab Labs in K-12 education aligns with the Mens et manus philosophy by providing students with opportunities to apply theoretical knowledge to real-world applications through hands-on experiences with digital fabrication technologies. The adoption of the proposed Fab Labs constructionist framework can help prepare students for the demands of a rapidly changing world and aligns with educational standards for science and mathematics.

On the Indeterminate Training Technologies of a Reconstructed Bauhaus Choreographer. A Research Practice Between Speculative Historiography, Architectural Invention, and Performative Co-enactment

This exposition proposes a method of artistic research that uses (and disobediently misuses) techniques of reconstruction as a mode of performative, artistic, and architectural invention. Our speculative notion of reconstruction challenges inherited disciplinary notions of historiography and simultaneously functions as a propositional and generative tool. The exposition revolves around the discussion of a research and performance project entitled Jakob K., which reconstructs the works of fictional Bauhaus choreographer and gymnastics teacher Jakob Klenke (1874–1941). This reconstruction was the product of a collaboration between performance artists and architectural researchers, involving field work, site-specific re-enactment, 3D scanning, animation, and digital fabrication, and culminated in a series of live performances at Kampnagel (Hamburg) and during the 2019 Bauhaus 100 centennial. The exposition is structured around a series of multimedia sections, each of which departs from an element of the performance’s architectural and medial framing, describes aspects of the artistic research process, and uses these as a lens for theoretical reflection. In analogy to our working method, which created the project as an ongoing layering of spatial and choreographical ‘evidence’, this method of discussing the project consecutively adds layers and connections to the project-assemblage that is Jakob K. Throughout the exposition, a practice emerges that challenges notions of solely human-authored and human-centred design and performance; proposes a set of techno-speculative training practices while challenging historical discourses on body optimisation; and subverts disciplinary uses of technology, prescriptive logics of representation, and techniques of reconstruction, misusing them instead in disobedient ways and reinventing them as creative affordances that can challenge dominant techniques of power.

RECORDING MICHELANGELO'S DAVID: ULTRA-HIGH RESOLUTION 3D SCANNING AND MODELING FOR DIGITAL AND PHYSICAL REPRODUCTION

Abstract. In the twentieth century, the physical reproduction of a work of art was considered only a business activity and a replica would rarely be on display in a museum. In recent decades, however, as high-resolution digital sampling and fabrication techniques have become popular in all fields, the various ways in which they can be applied to cultural heritage are leading to a more articulated approach to their use. They are no longer considered fakes or imitations, but as artefacts specially designed and built to facilitate the dissemination of heritage or perform simulations without damaging the originals. This case study describes the process of creating the replica of Michelangelo's David that has been displayed in the Italian Pavilion at EXPO 2020 in Dubai. Starting with the planning of the survey, the instruments and facilities used, and the fieldwork process are described. The resulting data have been then processed to produce a model optimised for replication on a large format additive manufacturing printer. Finally, the challenges of processing and managing ultra-high-resolution data are outlined.

Learning-by-Doing using 3D printers: Digital fabrication studio experience in architectural education

With transition to Industry 4.0, the usage area of Three-Dimensional (3D) printing technology has shown a rapid increase recently. Apart from scientific fields such as engineering, architecture and medicine, it has expanded its scope in many other fields. The aim of the study is to provide pedagogical guidance to educators and students by presenting a three-dimensional printing education as a case study in the digital design studio course as well as to make the students experience the Learning-by-Doing processes. This case study focuses on the importance and integration of 3D printing technology into undergraduate architecture education and seeks to strategically integrate this technology into the curriculum. The results of the study showed positive student responses to the inclusion of 3D printing and the use of 3D modeling techniques, which increased students' interest and participation in their projects and improved their understanding and visualization of design concepts. According to the results, 76% of the students, who took the course, were observed to make significant progress in the use of 3D modeling tools, 75% of them found solutions to the problems related to making 3D models printable and 69% of them made progress in converting their designed models into 3D.

THE POTENTIAL OF REVERSE ENGINEERING AND DIGITAL FABRICATION FOR THE REPAIR OF HIGH-TECH ARCHITECTURE

Abstract. Novel façade constructions and innovative load-bearing structures of the second half of the 20th century pose new challenges for maintenance and repair. The use of advanced technology, especially in High-Tech architecture, calls for the development of specific repair methods adapted to specific building materials and construction techniques. The conservation of these aging facades, often composed of custom-made metal components, requires the production of intricate spare parts to avoid unduly replacements. Digital fabrication presents a possible solution as it allows for the resource-efficient production of complex and non-planar geometries in small numbers while remaining cost-effective. The paper explores the use of photogrammetry and laser scanning to reverse engineer spare parts, as original plans are often missing or incomplete. A complete workflow for the fabrication of bespoke metal components is described using two examples of Swiss High-Tech architecture featuring challenging structural nodes and planar aluminum panels. Finally, the feasibility of remanufacturing spare parts is demonstrated with 3d-printed models.

COLLABORATIVE TEAMWORK PROTOTYPING AND CREATIVITY IN DIGITAL FABRICATION DESIGN EDUCATION

AbstractDigital fabrication laboratories play a role as an educational environment in which different learning activities incorporate advanced technological developments. Digital fabrication design education often involves exploratory and scaffolded processes of materialising ideas into products. However, FabLabs poses multiple challenges for pedagogy and design learning. Based on a large-scale digital fabrication course in a higher education institution, we examine whether teamwork carried out in a digital fabrication environment improves creativity. Furthermore, we analyse if teamwork affects self-assessment of learning activities involving building tangible artefacts. Finally, we examine whether the type of produced prototype affects the team's overall performance. The results allow for digital fabrication design education recommendations, including interventions intended for improving the creativity of the outcomes, team performance, and learning of different digital fabrication issues.

Digital design and fabrication of clay formwork for concrete casting

This paper investigates the potential of clay extrusion as formwork for casting customized and building-scale fiber-reinforced concrete elements. Customizable shapes are produced using clay as cheap, sustainable, and easily demoldable formwork, extending its printable height limit. The coupled incremental clay 3D printing and concrete casting process allows the layered casts to start curing and reduces the hydrostatic pressure from concrete. The concluding case study, the Cocoon, demonstrates the method’s capability to achieve building-scale height, integrate openings, and create complex surfaces. The introduced method seeks to challenge techniques and materials for 3D-printed formworks, demonstrating the ability to reduce the environmental impacts of concrete construction without compromising the complexity and time efficiency of bespoke elements.

Needles to Say

Story telling and informal learning is passed down generations and has been recognized as the best approach for human evolution and development. Its efficient process has made its impact and has demonstrated its benefits scientifically at the DNA level. There are scientific publications that attribute human evolution to this DNA based memory, making humans thrive on this planet as dominant species with emotions and care. One such form of storytelling and informal learning is folk quilting which has an extensive history. The power of storytelling and informal learning over generations helped quilters acquire their sense of identity, belonging with a deep sense of felt values. Every patch in a quilt is a story to say invoking memories presenting a living tradition in the folk world. The story of quilts are not just personal appeal to those who stitch but symbol of care, comfort, and inspiration to their loved ones and to those who eventually own them. Community of collaborative quilters within families and guild collectives resonate to social values; patience, connectedness and expression that are central to the form. Hybrid networks of quilting communities in developed countries maintain integrity of social values different from that of traditional folk quilters in developing countries due to the very nature of digital accessibility. With the growing global market, native folk quilters are approached by the creative industries with a certain sense of urgency. Creative technological tools are introduced to meet the demand for increased production. With market driven production, care and collaboration are in question. To top it all, as digital immigrants, traditional folk quilters struggle with technological adoption as they are already threatened to survive and sustain the purity of the indigenous form. They now are further challenged to impart their sense of effective passing down of traditions to their younger generation with the care different from their own. Adopting technology on their own terms is no easy feat, as makers of technology don’t necessarily see folk artists as their primary users. As part of my research into creative technology influencing quilters, I hope to draw on transdisciplinary methodologies ranging from textual analysis of case studies from India and North American folk art history, folk feminist ethnography, cultural studies, ethno-mathematics and digital fabrication. I will be interviewing folk quilters, quilt guilds, artists, designers and technologists to understand the complex dynamics of the interplay of social values, aesthetics, technology and production. In my proposed paper, I will share voices from the field that will examine the changes in the process of how memories and stories are told with the coming of new digital tools and technology and a reaction on how to take forward care for cultural nature of this rich artistic tradition to their own communities through living practitioners. These voices could help transfer the cultural nuances to creative technologists in ways that inform their design processes such that they improve the chance of technology success amongst folk artists for creative production, discourse building and folk quilting pedagogy to sustain and thrive.

Qualitative technology evaluation of digital fabrication with concrete: Conceptual framework and scoreboard

The adoption of digital fabrication with concrete (DFC) has the potential to bring sustainability, productivity, and process innovation to the construction industry. However, DFC adoption towards market-ready construction systems is lagging due to a lack of understanding in matching its technology capabilities with the needs of potential adopters. This paper describes a DFC Evaluation Framework, analyzing current advancements in DFC through a Conceptual Framework Analysis. The framework is focused on the inputs, process parameters and outcomes of a given technology solution independently of the enabling technology type. It can be used to classify and compare DFC technologies along their systemic characteristics, which are both technical and non-technical in nature. The DFC Scoreboard, an interactive tool to match DFC technologies with the needs of prospective adopters, is developed and tested based on the framework. The paper discusses how the DFC Evaluation Framework and Scoreboard offer one of the first systemic overviews of DFC adoption, with the capability to match technology capabilities and user needs in the technology adoption process.

Set-on-demand of alkali-activated slag mixture using twin-pipe pumping

To achieve the set-on-demand purpose of concrete for digital fabrication where the opposing requirements for pumpability and buildability exist during the process, an inline mixing strategy, named twin-pipe pumping, has been developed utilizing a static mixer to blend two separate streams to accelerate setting right before extrusion. The system was initially developed utilizing two streams including a Portland cement-based mixture (without accelerator) and a limestone powder-based mixture (with an accelerator but without cement). However, the high content of cement may result in higher material costs along with lower sustainability, given the fact that the production of Portland cement contributes to around 8% of global CO2 emissions. This study aims to develop an alkali-activated slag mixture to increase the sustainability in digital fabrication, using twin-pipe pumping. The constituent mixtures consisting of a slag-based (without alkali) and a limestone powder-based (with varying alkali content) mix were formulated and their rheological behavior was measured for good pumpability. Phase transition from liquid to solid phase, mechanical strength, and pore structure was evaluated. Twin-pipe pumping was used in a printing trial. Results showed that the alkali-activated slag mixture achieved fast phase transition for set-on-demand purposes by combining the alkali in the limestone-based mixture with the slag in the slag-based mixture. Increasing the NaOH concentration or incorporating nano clay improved the structural build-up for high buildability.

Physical-Digital Programming

Scientists, artists, and engineers are innovating with digital fabrication machines, yet they lack effective tools to program machines for unconventional tasks. We argue for programming language foundations to empower these practitioners to build bespoke fabrication workflows for themselves.

Assessment of the Effect of two Different Digital Fabrication Techniques on Marginal and Internal Fit of Interim Fixed Dental Prothesis

Assessment of the Effect of two Different Digital Fabrication Techniques on Marginal and Internal Fit of Interim Fixed Dental Prothesis

Early Stages of the Fablab Movement: A New Path for an Open Innovation Model

FabLabs, also known as digital fabrication laboratories, are a groundbreaking phenomenon that is contributing to the democratization of innovation and technology. Despite their potential influence, this emerging area has received little attention in the literature. This paper examines the initial stages of the FabLab movement using a mixed-sequential exploratory methodology. Qualitative methodologies were employed to identify relevant dimensions and establish research hypotheses, while quantitative methodologies were used to evaluate and validate these hypotheses and generate a predictive model for the innovation process through binary logistic regression. The information obtained through the participation of 124 laboratories in the online FabLab Global Survey was used. The results indicate that collaborations with large companies and a majority focus on research in FabLab projects promote the development of innovative projects compared to those laboratories affiliated with educational institutions or primarily used by students.

A Study of Free-Form Shape Rationalization Using Biomimicry as Inspiration.

Bridging the gap between the material and geometrical aspects of a structure is critical in lightweight construction. Throughout the history of structural development, shape rationalization has been of prime focus for designers and architects, with biological forms being a major source of inspiration. In this work, an attempt is made to integrate different phases of design, construction, and fabrication under a single framework of parametric modeling with the help of visual programming. The idea is to offer a novel free-form shape rationalization process that can be realized with unidirectional materials. Taking inspiration from the growth of a plant, we established a relationship between form and force, which can be translated into different shapes using mathematical operators. Different prototypes of generated shapes were constructed using a combination of existing manufacturing processes to test the validity of the concept in both isotropic and anisotropic material domains. Moreover, for each material/manufacturing combination, generated geometrical shapes were compared with other equivalent and more conventional geometrical constructions, with compressive load-test results being the qualitative measure for each use case. Eventually, a 6-axis robot emulator was integrated with the setup, and corresponding adjustments were made such that a true free-form geometry could be visualized in a 3D space, thus closing the loop of digital fabrication.

Makerspaces and Making Data: Learning from Pre-Service Teachers’ STEM Experiences in a Community Makerspace

As the student population in the United States (US) is becoming more diverse, educator preparation programs are seeking ways to make the teacher workforce more diverse, which involves diversification of training experiences. Informal spaces, which can include integrated science, mathematics, engineering and technology (STEM) opportunities, are not traditionally part of teacher preparation, although teachers are being asked to occupy these STEM spaces with more frequency. Including informal experiences in a community STEM makerspace, which highlights digital fabrication, creativity, and problem solving, diversifies teacher preparation by extending beyond both the university setting and the elementary classroom. This exploratory case study with elementary (primary) pre-service teachers in a science and math methods (vis a vis STEM) class examines experiences they have in a community makerspace in a qualitative study, which uses Data Engagement (DE) as a methodological framework. DE draws upon intersectional feminist, critical, and materialist theories. Assembled and made data from observations in the makerspace, pre- and post-maker reflections, and responses to a modified in-person interview protocol reveal that, despite more open-ended and complex challenges than those experienced in class, participants reported positive future-thinking, less content dread, and more agency in perceived efficacy. These results invite further study and conversation about including informal STEM maker experiences in US teacher preparation as a step to increasing diversity in the teacher workforce.

3D Printer

Digital fabrication technology, also referred to as 3D printing or additive manufacturing, creates physical objects from a geometrical representation by successive addition of materials. 3D printing technology is a fast-emerging technology. Nowadays, 3D printing is widely used in the world. 3D printing technology has been increasingly used for the mass customization, production of any types of open-source designs in the field of agriculture, in healthcare, automotive industry, locomotive industry and aviation industries. 3D printing technology can print an object via layer-by-layer deposition of material directly from Computer Aided Design (CAD) model. This paper presents an overview of the types of 3D printing technologies, the application of 3D printing technology, and the materials used for 3D printing technology in the manufacturing industry.