Posts tagged with "3D Printing":

Placeholder Alt Text

How Synthesis Design + Architecture and Formlabs crafted this year’s Best of Design Awards Grand Prize

At this year’s Best of Design Awards, winners were selected from 27 categories and each will take home a bespoke AN awards 3-D-printed trophy designed by Los Angeles studio Synthesis Design + Architecture (SDA) and fabricated by Somerville, Massachusetts–based printers Formlabs.

Founder and design principal of SDA and an assistant professor at the USC School of Architecture, Alvin Huang and his team settled on a final design after initially drafting up more than 20 ideas.

“We wanted to create an intricate, detailed form—something that would be impossible to do without a 3-D printer,” Huang said. To produce the design, Formlabs used transparent resin to reveal the design’s inner complexities. As part of his design process, Huang devised numerous iterations. “Parametric modeling makes everything smoother,” continued Huang.

The original design intent explored three-dimensional line drawings using modeling software such as Rhino and Grasshopper. However, after a number of tests, Huang ruled out this technique because of the laborious quantities of support material that were required to print. Instead, he employed a process that explored the variable scaling and extrusion of 2-D text to create a cloud of 3-D forms.

“It was important due to the time constraints that we revise the design of the trophy to match the constraints of the printing process of the machine. The change in direction allowed us to drastically reduce the amount of waste material printed (in the form of support structure) as well as the printing and post-production time,” Huang said.

The technique capitalized on the vertical movement of the material through the 3-D printer, enabling the detailed, intricate geometries of the individual letters to collectively form the trophy. The variable parameters that drove the model were the height of the extrusions, the scaling of the letters, and the density of the underlying matrix.

Huang was also pleased to work with Formlabs, which will be producing the physical award. The studio’s high-resolution 3-D printers made Huang’s design, in his words, “easy to achieve” and “smoothed out the processing of the designs.”

Zach Frew of Formlabs said, “We wanted to push the limits of 3-D printing with Synthesis’s design. This means that we started with the highest level of complexity and iterated downward—evaluating any changes needed in the design after each print. 3-D printing allowed us to rapidly develop prototypes and progress towards the final design.”

Frew continued, explaining that Formlabs’ high-resolution printers allowed Huang creative freedom. “Traditional manufacturing techniques are restricted in the level of complexity and detail they can achieve. Older subtractive technologies like CNC tooling are unable to resolve intricate details or create complex internal structures.”

“Because 3-D printing is an additive technology that produces one layer at a time with precision, more complex geometries can be created,” he said. “Synthesis’s design takes advantage of this. The Form 2 [printer] offers a very high level of detail and precision that makes relational designs easier and more reliable to produce. The machine typically produces parts with less than 200 microns of deviation from the original model. This means that designers can be confident that their models will function and relate as designed. SLA printed parts are also much easier to sand and post-process so modifications can quickly be made.”

Despite its prowess in the niche field, Formlabs prints more than just trophies. “3-D printing excels at creating rapid prototypes and visualizations,” added Frew. “Architects are able to produce scale models of their designs and ensure that each of the parts interact as desired. Printing tangible models that previously only existed within design software is an invaluable tool for helping architects to evaluate and iterate on their designs.”

Placeholder Alt Text

SHoP Architects announced as winners of the 2016 Panerai Design Miami/ Visionary Award

New York-based SHoP Architects has been named as this year's winners of the Panerai Design Miami/ Visionary Award. Now in its third year, the award recognized SHoP for their "bold, evocative architecture, philanthropic initiatives, sustainable development, and innovative practices/entrepreneurship." As a result, the firm will get to see their installation, Flotsam & Jetsam built in the Miami Design District's Jungle Plaza. In their 20 year history, SHoP has had projects built across the U.S. but has found most success in New York City. Currently, a super tall mixed-use tower is going up in Brooklyn—the borough's first. "SHoP is a place where people come together without any prescribed idea about what the esthetics of a building or public space should be, then we take complex problems and solve them with both beauty and technical proficiency," SHoP Founding Principal Gregg Pasquarelli said in a press release. "Working with Design Miami has been a great experience and a perfect opportunity to explore the expressive possibilities of tomorrow's architecture." Using Chattanooga-based 3D printing and fabrication firm, Branch Technology, Flotsam & Jetsam looks to push the boundaries of the 3D-printed medium (especially in terms of scale). The installation—stylistically reminiscent of work by Marc Fornes & Theverymany—sees a series of arching bamboo legs join to form a canopy and seating area. The bamboo however, is no ordinary bamboo. SHoP chose Oak Ridge National Laboratory (ORNL) to supply a biodegradable bamboo 3D print medium. This method of construction can produce forms on an unprecedented scale, and when built, SHoP's Flotsam & Jetsam will be the largest 3D-printed structure in the world. Located in the Jungle Plaza, the installation will play host to an outdoor cultural event space. Here, talks, performances, and cocktail events will take place. SHoP's work will also be launched with the Institute of Contemporary Art, Miami (ICA Miami) in Spring/Summer 2017 along with a community program for bringing "world-class" public sculpture to the city. SHoP will be presented with their award at the Design Miami/ press reception on Tuesday, November 29. “SHoP represents exactly what the Panerai Design Miami/ Visionary Award is meant to recognize: innovation, inspiration and an outstanding point-of-view,” said Rodman Primack, chief creative officer, Design Miami/. “For the first time, we will be installing the commission long-term in the Miami Design District and I cannot think of a better practice to conceive this installation. We are thrilled with the pavilion design and delighted to honor SHoP for the 12th edition of Design Miami.”
Placeholder Alt Text

Tennessee startup plans to 3D print house

Tennessee-based Branch Technology has announced it will begin construction of a 3D-printed house in 2017. Designed by Honolulu-based WATG, the project was initiated for the Freeform Home Design Challenge, which asked participants to design for Branch’s Cellular Fabrication (C-Fab) 3D printing technology. The small house designs were required to be between 600 and 800 square feet. Branch’s C-Fab technology involves 3D printing carbon-fiber-reinforced ABS plastic with a large robotic arm. The resulting formwork can then be covered in more traditional building materials, such as concrete or foam. Instead of the typical completely 3D printed additive technique, C-Fab uses an algorithm to formulate an interior framework for the structure. WATG’s design, entitled Curve Appeal, will be built at Branch Technology’s lab in Chattanooga, Tennessee. The house is comprised of a curving shell around an open plan. The form of the building also provides a car port. The interior of the house is divided up with class walls and a solid core.

CURVE APPEAL by dcaven on Sketchfab

Placeholder Alt Text

New 3D printing software churns out giant projects in one pass

Fabricators watch as an artificial hip joint comes together on the tray of a 3D printer.  This, doctors say, is the high-tech future of joint replacement. The printer's lone nozzle squirts plastic polymer out into the precise shape. However, in the time it takes to make a new joint, you could watch half a season of The Bachelor, or drive from New York City to eat poutine in Montreal. One company is addressing the time barrier with a new software that enables faster, and much bigger, 3D printing. https://vimeo.com/157523884 Autodesk is creating a 3D printing system, dubbed Project Escher, will be able to create large objects in one pass. Project Escher divides larger designs into smaller instructional packages. The packages are sent to groups of printheads which work in tandem to produce the finished object. This factory-line approach speeds up the often painstakingly slow printing process for large, high-resolution pieces. The customization goes further: Project Escher's printheads are modular, making it easy to swap out different tools. For example, you could swap a printhead with a tool that removes supporting structures while the other five printheads churn out a product. This video shows just how this would happen. Printing large objects could have positive ramifications for architects: facades like this one could be fabricated in one session. Ornate wall-to-wall moldings or whole ceilings could be reproduced without interruption. Currently, larger-scale 3D printing is currently employed by archeologists replicating ancient buildings destroyed by ISIS in the Syrian city of Palmyra. To be clear, Autodesk is not building a new printer, just the software. The printer-savvy can build their own machines to accomodate the software, mere amateurs will have to wait for the hardware to catch up.
Placeholder Alt Text

This 3D-printed sundial casts a shadow that looks like a digital clock

Even for the old-school sundial, analog is out and digital is in, in a manner of speaking. French Etsy retailer Mojoptix has created a 3D-printed sundial that uses an intricate system of holes to display time like a digital clock, no batteries needed. Using an extraordinarily articulated dial, the apparatus uses light and shadow to display the time in 20-minute increments between 10:00a.m. and 4:00p.m. Mojoptix's not-so-digital sundial takes 35-hours to print and each one is made individually, something the shop describes as requiring "a lot of patience." Fulfilling your sundial trivia needs, Mojoptix's device is technically a "gnomon," the shadow-casting portion of the ancient tool. The company prints these gnomons on Ultimaker 2 3D printers using 0.1mm and 0.2mm layers of ABS plastic. "No batteries, no motor, no electronics... It's all just a really super-fancy shadow show," says Mojoptix. "The shape of the sundial has been mathematically designed to only let through the right sunrays at the right time/angle. This allows to display the actual time with sunlit digits inside the sundial's shadow." https://youtu.be/wrsje5It_UU
Placeholder Alt Text

The Future is Now: Here’s what caught our eye at this year’s Consumer Electronics Show

This month's Consumer Electronics Show (CES) brought more than 170,000 attendees to visit over 3,600 exhibitors. Navigating a sea of similar tech products may seem overwhelming, but there are a few products to note within the realms of smart home technology, 3D printing, and electronics to improve one’s health. House of the Future Nearly a Reality Still no self-cleaning floors, but a Jetson-like future is not far off with systems like Vivint, which syncs most of the controls in your home to your smartphone. Not only do these systems offer doorbell and ping security cameras that include two-way talk, you can also control the garage door, lighting, temperature, and DVR remotely. The newest addition to the Vivant family is the integration of Kwikset Smart Locks, the Nest Learning Thermostat, and the Amazon Echo. To keep things clean top to bottom, WINBOT is a new robot that cleans framed and frameless windows as well as horizontal glass surfaces and mirrors. All you have to do is spritz the cleaning pad, switch it on, and place it on the window. The bot does the rest by automatically scanning and calculating the size of the window or surface. Samsung debuted the Family Hub Refrigerator that brings a bunch of sci-fi tech to real life. With a 21.5-inch HD LCD display on the exterior, you can post family photos and calendars as well as stream music and watch live TV; so you never have to miss a moment of the big game or award show while refilling on snacks. One of the most impressive features is the set of three interior cameras that take photos every time the door is closed. Next time you are at the grocery store and can’t remember if you are out of milk, just peer inside the fridge from your smartphone screen. Skydrop, the new smart sprinkler controller, monitors local weather data and automatically sets the perfect time and amount of water its yard receives. The system can reduce water usage by 50 percent, which saves money while aiding the environment. Let’s Get Physical  Knowing how many steps walked or calories burned in a day is so yesterday. With iHealth’s collection of medical-tech accessories, users can monitor every aspect of their health including blood pressure, glucose levels; weight and BMI; sleep, and blood oxygen levels. With the MyVitals app all data can be viewed in one place and easily shared. Swarovski has released activity tracking jewelry, called Shine, that transforms from watch to necklace to bracelet all while wirelessly syncing with the wearer’s smart phone. Humanscale has created two products that work in tandem to increase productivity and psychical activity in the workplace. The QuickStand Lite transforms any fixed-height desk into a standing desk, and can be moved easily allowing for users to sit or stand as often as necessary. The OfficeIQ was created in collaboration with Tome Software and uses sensor technology to gather data on sit-stand use. It measures caloric expenditure and sends real time notifications to users, reminding them when they have been seated too long. Print it Out 3DSystems recently released CubePro, a large-format printer that makes printing professional quality models at home a snap. Especially with new printing materials that include nylon, rinse-away support, and wood composite materials. The Nylon material is a flexible and long-lasting medium for functional prototyping. Rinse-Away allows designers to achieve intricate patterns that are easy to remove and leave no“support stubble”” residue. Lastly, its wood composite material can be sanded, nailed, drilled, stained, and painted to make artistic creations. Big news for those of us who are not in the position to buy large-scale printing devices, or have too much work for a home printer to handle. UPS is now offering over 60 printing locations in the U.S. that can quickly and efficiently turn 3D files into models.
Placeholder Alt Text

A giant 3D printer will replicate an ancient temple destroyed by ISIS

Replicas of the entrance arch of the ancient Temple of Bel in Palmyra, Syria, will be recreated using a giant 3D printer for World Heritage Week in London and New York. The recreations are intended to defy the actions of extremist group the Islamic State in Iraq and Syria (ISIS), which destroyed a large portion of the nearly 2,000-year-old temple building in August of last year. The arch, which is nearly 50 feet high, is one of the few relics standing after ISIS sought to systematically destroy Palmyra in an effort to erase the pre-Islamic history of the Middle East. https://twitter.com/middleeasthist/status/683281394202742784 Before the conflict in Syria ignited in 2011, Palmyra’s rich cultural heritage drew more than 150,000 tourists each year. The temple, which was founded in A.D. 32 and consecrated to the Mesopotamian god Bel, was exemplary of the fusion of Middle Eastern, Greek, and Roman influences and was considered to be one of the most important sites in Palmyra. The temple was converted into a Christian church during the Byzantine era, and then into a mosque when Islam arrived around the 7th century. In recent times, the Temple of Bel was an important cultural venue for Syrians, acting as a setting for concerts and events. The Institute for Digital Archaeology (IDA), a joint venture between Harvard University, the University of Oxford, and Dubai’s Museum of the Future that promotes the use of digital imaging and 3D printing in archaeology and conservation, is taking the lead on the recreation efforts. Last year, the organization collaborated with UNESCO in the distribution of 3D cameras so that volunteer photographers could document threatened cultural objects in areas of conflict in the Middle East and North Africa. The images are to be uploaded to a “million-image database” for use in research, educational programs, and ultimately 3D replication, as in the case of the Temple of Bel. Although the Temple of Bel was demolished before photographers with 3D cameras could capture it, researchers at the IDA have been able to create 3D approximations of the temple using ordinary photographs. The full-size replica arches, to be made from stone powder and a lightweight composite, will be created off-site and then assembled in Trafalgar Square and Times Square for display this April.
Placeholder Alt Text

Dreams bend into furniture with this Inception-style coffee table

The frontier-era drama The Revenant, starring Leonardo DiCaprio and Tom Hardy, may have won best picture at last night’s Golden Globes, but it’s the actors’ 2010 mind-bending film Inception that has inspired some seriously cool (yet questionably practical) furniture. The “Wave City Coffee Table,” created by Cypriot-based designer Stelios Mousarris, emulates the scene from the Christopher Nolan–directed thriller in which Ellen Page’s character Ariadne, a student at the Ecole Speciale d’Architecture in Paris, “messes with the physics” of a dream. The resulting bent cityscape mesmerized audiences around the world—and now around the coffee table. This cantilevering wood and steel table features an urban landscape bending over itself, as depicted in the film. https://www.youtube.com/watch?v=x9hBWnh_O6A Mousarris, who previously worked for Foster and Partners as a modelmaker and for Duffy London as an assistant designer, created the unusual piece using 3D printing technology. His other work proves just as unique, and includes the “Carpet Sofa,” which can be custom-made with a carpet that fits your individual space, and the “Half Couch,” which is described by Mousarris as balancing on one side “whilst perfectly supporting the human weight on the other side.” The limited-edition table is available for purchase on the designer’s website for €5,000, although you may only be able to afford it in your dreams.
Placeholder Alt Text

Learning from AMIE: a look into the future of 3d printing and sustainable energy management

A high-performance building prototype which shares energy with a natural-gas-powered hybrid electric vehicle.

A cross-disciplinary team at Oak Ridge National Laboratory (ORNL) have designed an innovative single-room building module to demonstrate new manufacturing and building technology pathways. The research project, named Additive Manufacturing Integrated Energy (AMIE), leverages rapid innovation through additive manufacturing, commonly known as ‘3d printing,’ to connect a natural-gas-powered hybrid electric vehicle to a high-performance building designed to produce, consume, and store renewable energy. The vehicle and building were developed concurrently as part of the AMIE project. The goal of AMIE was twofold according to Dr. Roderick Jackson, Group Leader of Building Envelope Systems Research and Project Lead for the AMIE project at ORNL: “First, how do we integrate two separate strains of energy: buildings and vehicles; and secondly, how do we use additive manufacturing as a way to create a framework for rapid innovation while not becoming constrained by the resources of today?” Additive manufacturing contributed to formal expression of the building envelope structure and offered efficiencies in material usage while significantly reducing construction waste. Jackson says the design and manufacturing process became embedded into the ‘rapid innovation’ spirit of the project. “The architects at SOM worked hand in hand with the manufacturing process, sharing the building model with the 3d printers in the same way that the vehicle shares power with building. For example, within the course of less than a week, between the manufacturer, the material supplier, the 3d printers, and the architects, we were able to work together to reduce the print time by more than 40%.” In total, the AMIE project – from research, through design, manufacturing, and assembly – took 9 months.
  • Facade Manufacturer Oak Ridge National Laboratory
  • Architects Skidmore, Owings & Merrill LLP
  • Facade Installer Clayton Homes (assembly)
  • Facade Consultants Oak Ridge National Laboratory (research), Skidmore, Owings & Merrill LLP (design)
  • Location Oak Ridge, TN
  • Date of Completion September 2015
  • System 3d printed atmospherically insulated panels (AIP), post-tensioning rods, photovoltaic (PV) roof panels
  • Products 20% carbon fiber reinforced ABS plastic
The building incorporates low-cost vacuum insulated panels into an additively manufactured shell, printed in 2’ widths in half ring profiles, assembled at Clayton Homes, the nation’s largest manufactured home builder. The vacuum insulated panels consist of Acrylonitrile butadiene styrene (ABS) with 20% carbon fiber reinforcement, a material which serves as a “starting point” for Jackson and his team: “We wanted to open up the door for people to say ‘what if?’ What if we used a non-traditional material to construct a building? I see this product as a ‘gateway.’ This might not be the final material we’ll end up using to construct buildings in the future. We’ll need to find locally available materials and utilize more cost-saving techniques. But we had to start somewhere. The ABS product will open the door for a conversation.” The project emerged out of fundamental questions concerning access to, and use of energy. Climate change, an increasing demand for renewable energy sources, and uncertainty in the balance of centralized versus distributed energy resources all impact the grid. In addition, more than 1.3 billion people worldwide have no access to an electric grid, and for an additional billion people, grid access is unreliable. AMIE will doubly function in the near future as an educational showcase to both the public who will learn of its story, and ORNL researchers who will continue to monitor how energy is generated, used, and stored. Will there be an AMIE 2.0? Jackson responds: “We don’t look at this as a one hit wonder. We really want this research to be the first stone thrown in the water that causes a ripple throughout the disciplines involved. Not only for us, but throughout the world. We want to put this out there so other smart people can look at it and brainstorm. If the end of the next project looks anything like AMIE 1.0, then we’ve missed the boat.”
Placeholder Alt Text

Two Words: 3D Chocolate

Chocolate purveyor Hershey has jumped onto the 3D printing bandwagon. While not as aesthetically ambitious as Nendo's venture into custom sweets, there's something to be said for remaining true to the iconic, albeit simple, kiss-shaped treat. Initial ventures took from a few minutes to more than an hour to print; if you're really hankering for a chocolate fix, you might be better off grabbing a bag of the pre-fab variety. https://youtu.be/ovg19Ehjo7U
Placeholder Alt Text

MIT’s new ‘MultiFab’ 3D printer breakthrough capable of molding 10 materials at once

Soon, we might have 3D copy machines. Using powerful new technology, MIT's latest 3D printer boasts, according to Russia Today, almost "human-free usability" which allows it to print "ready to use" objects comprising of up to ten different materials. https://youtu.be/poRFPjiB9vw The development is being described by Gizmodo as a "giant leap" towards real-life replication as 3D printers strive for the ultimate goal of being able to produce functioning electronic parts. Already printers are capable of producing electronic circuits, however, MIT's printer named 'MultiFab' (echoing the name of the 'MultiVac' super-computer in Isaac Asimov's science fiction novel, The Last Question) is able to integrate these circuits into actual electronic components. This simplification of the manufacturing process hints at a future where a press of a button will be enough to produce such electronic mechanisms. A 3D scanner is also incorporated into the printer which allows the device to print onto existing components. This could mean that making future modifications to your smartphone, for example, is a very real possibility. Another advantage of this feature is that the printing process can be almost hands free. The scanner works in real time to make sure everything is aligned, telling the printer to make changes if necessary. In a release by the Computer Science and Artificial Intelligence Lab (CSAIL) at MIT, the research team has described their printer as, "high-resolution, low-cost, extensible, and modular."  Advocating its possible use in education they also said that "students and teachers will be able to create complex mathematical figures, physics sets, lens systems, and anatomical models."