design, computation and computer controlled devices · 2019. 9. 12. · stereo lithography [ why...
TRANSCRIPT
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4.212
Design Fabrication Design, Computation and
Computer Controlled Devices
Prof. Larry Sass Department of Architecture and Planning
MIT
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LECTURE #3
The Problem?
Rapid Prototyping
Tolerance
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[1]
Why rapid prototyping?
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[ CAD ]
software -- Rhino -Microstation -
hardware
Autocad
FormZ
[ CAD CAM ]
Glymph/Shelden Kolarevic Burry
software -Catia - Unigraphics -SolidWorks -ProEngineer
NC hardware -Plasma cutter - NC milling -NC routing -Waterjet Cutting
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[ why rapid prototyping? ]
1. visual representation
2. relationship between building methods and simulate performance
3. allows for the study complex design possibilities
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Issues
should the process reflect the design problem?
can the first cut be the last cut?
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research project
Rapid Prototyping continuous curved surfaces models
summer, 2002
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[research observation ]
The Experience Music Project Architect: Gehry Partners
- CAD CAM manufactured surface and structure
- overlapping surfaces
- surface is a rain screen
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[research question ]
- can curved surfaces be modeled in a design office?
- is it possible to have a continuous surface with no overlapping parts?
- can the surface be waterproof?
- does a rapid prototyping process reflect methods used in the field?
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[ create surface ]
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[ sub-divide surface ]
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[ mold blocks ]
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[ mold blocks ]
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[research results ]
Simulation of a Continuous Glass Surface
1. Introduction of the hand was cause for a high number of surface errors
2. Visually correct position of surface components
3. Inconsistent connections at joints
4. Plastic had a hard time during double curving
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[field example of inconsistant surfaces manufacturing]
Graz Museum Architect: Peter Cook
- CAD CAM manufactured surface and structure
- no overlapping surfaces
- surface is a rain screen
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[observed results ]
Simulation of a Continuous Glass Surface
1. Introduction of the hand was cause for a high number of surface errors
2. Visually correct position of surface components
3. Inconsistent connections at joints
4. Plastic had a hard time during double curving
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[recommendations ]
Continuous Glass Surface
A. Full CAM or RP process
B. Molds and Cuts in one process
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[ CAD ] [ CAD
software -Catia ---ProEngineer
-Plasma cutter - NC milling -NC routing -
software -- Rhino -Microstation -
hardware -Paper camm -Laser Cutter -- FDM -
Waterjet Cutting
rapid prototyping
CAM ] nc tools
Unigraphics SolidWorks
NC hardware
Autocad
FormZ
3D Printer
Stereo Lithography
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[ why rapid prototyping? ]
1. visual representation
2. relationship between building methods and simulate performance
3. allows for the study complex design possibilities
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[2]
Rapid Prototyping
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[recommendations ]
Rapid Prototyping Devices
Addition (building)
Subtraction (cutting)
Devices Goals
Rapid Representation vs Manufacturing
Visual and Usable representations
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Design Models Buildings
CAD CAD
Rapid CAD CAMPrototyping Devices
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z
Building Devices
-3D Printer - Metal - Cornstarch - Plaster - Ceramics
- FDM - ABS Plastic - Rubber - Wax
-Stereo Lithography - Resin
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ZCORP
-3D Printer - Metal - Cornstarch
-Plaster - Ceramics
Build
Feed
Slow Axis
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ZCORP
Overflow
Binder and Head
Build
Slow Axis Roller
Feed
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ZCORP
Open Spaces
Plaster
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-3D Printer Advantages- Speed
- Self Supporting
- Low Cost
ZCORP
-Disadvantages
- Low Strength
- Required Post Processing Wax
Plaster
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Strata Sys
-Fuse Deposition Modeling - ABS Plastic - Rubber - Wax
Material
Support
Head
Envelope
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Temperature Gauges
Control Board
Envelope
Z Table
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z
Head
Support
Material
Material
Support Base
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Heating Elements
Tips
Drive Wheels
Filament
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-Advantages- Strong
- Minimal Post Processing
STRATASYS
-Disadvantages - Slow
- Porous
- Hates Voids ABS Material .010
- High Cost to Operate ABS Support Base .010
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Power Supply
Stereolithography
Mirror
Mirror
Table & Polymer Vat
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Laser Source
Models
Vat
Table
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Laser Source
Skimming Knife
Mirror
Table & Model
Vat of Polymer
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STRATASYS
-Disadvantages - Cost
- Hates Voids
- High Cost to Operate
-Advantages - Strong
- Minimal Post Processing
- Supports very thin parts
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[3]
Tolerance
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Tolerance
- All Materials in Components Vary
- Range of acceptable tolerances
-All elements do not need to be of a fine tolerance
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Tolerance Classifications
- Material Tolerance - Cutting
-Assembly Tolerance
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Natural Features of Rapid Prototyping Devices
- Tight tolerances
-Self Assembly
-Can hold shape relationships
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1/8”
1/4” 1/32”
1/16”
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Tolerance
- Tight Fittings for fast model assembly
- Control of complex angles and assemblies