USE OF 3D PROTOTYPING IN ARCHITECTURE

3D Model making plays a vital role in Architecture which is equally important from learning phase to professional phase.  In learning phase, it gives clear idea of understanding the design and in professional phase, it gives picture of design before going to construction phase. The advancement of 3D modeling has helped to give an accurate picture of design. It gives an opportunity to modify the design as necessary which saves time and cost both. 3D models were generally made with paper, wood, plastic by hand which takes lots of time and effort.  The new technologies have created many 3D Object making machines which can create prototype in less time and with less effort. 3D Printings are the invention of new technology for making prototype in which the 3D model is extruded with numbers of layer. It can make detail 3D which is impossible with handmade one.

In this project, I have designed 3D of contour site (slope land) which has numerous contours of different height. I choose this model to use 3D print because it has always been challenging to maintain accuracy in contour shape while making with paper. And also it takes lots of time and effort to make this kind of 3D object. I used two kind of 3D Printing: uPrint and Solid Objet Printing.

uPrint:

uPrint is one of the easiest 3D prototype making machine. It uses ABS material; a production-grade thermoplastic which is tough enough for functional testing under real-world conditions. It can be drilled, machined, sanded and painted. They’re perfect for proof of concept, functional testing, product mock-ups and even making fixtures. It uses built material and support material, the support material can easily be dissolve in a soap and water based solution.

Solid Object Printing:

Solid Object Printing is a device that can print color 3D object. It consists of numerous numbers of layers which is compiled with powder material and form a whole object. It is mostly suitable if the product has to prototyped in colorful form.  It doesn’t require support material but requires glue solution to glue the powder particles and make it stronger.

In both printing process for MODEL ‘A’ AND MODEL ‘B,’ I created 3D with Auto Cad and saved into .STL extension file.

MODEL ‘A’

uPrint 3D printing was used to make model ‘A’.

Firstly, I created 3D model in Auto Cad and export into .STL extension file.

Steps used for printing in uPrint are:

• Open .STL extension file in CatalaystEX software.
• The CatalystEX has different tab which can be followed one after another.
• 

-         General: Select model fill and support style, change unit and scale if required.

-         Orientation: Object can be rotated and resize if required.

-         Pack: Add to pack button, the software will add the file to pack preview window. The printing object is shown in pack; object can be moved as necessary.

-         Printer Status : Display the amount of material left to be built both for model and support.

-         Printer Service: It gives the information about the printer history, time.

• The model material used was 12.67 sq.in and the support material used was 11.28 sq.in.
• Print is sent to build the model.

-         ‘Ready to Build ‘ will be displayed  indicating the model is ready to print.

-         Click on ‘ Start Model’ to begin printing in Display panel.

This is one of the simplest methods of 3D printing. Most of the steps can be easily followed one by other instructed by software tab. It took around 3 hours to build the model and it had 50 layers. After the printing is done, it should be carefully taken out from uPrint. As the object is made with support material, it should be removed dissolving in soap and water based solutions for sometime depending upon 3D object size and design.

But in this project, the support materials were only needed for base of the model. Therefore, it was not required to remove the support material.

—————————————————————————————————————————————————————————————————————

MODEL ‘B’

Solid Object Printing was used to make model ‘B’.

Firstly, I created 3D model in Auto Cad and export into .STL extension file. This is again a prototype of a contour land. As this printing has ability to produce the 3D object with different colors which give 3D object a real look. It not only gives clear picture of model but also helps to distinct the detail design elements.

Steps used for solid object printing are:

• Open .STL extension for 3D printing process with zprint software.
• Set the unit to use like inch, meter and then scale it if required.
• Steps were followed as instructed by the printing software to make sure that the printer is working properly and the printer is ready to print our object.
• 
• The print location can be changed as required.
• The 3d object can be edited with z edit if texture is required to be set through this software.
• After everything is set, the print can be done and estimate time to finish is also given.

It took around 3.5 hours to complete the 3D print and it had 250 layers. As it is in forms of compressed powder, the solution of glue (Z bond) was applied all over the model to make it strong.These are the pictures of final product before and after using glue.

These are only some prototypes I tried for understanding use of 3D prototyping in architecture but we can create many other different kinds of challenging design models which is impossible to make by hand.

Solid Object Printing

Solid Object Printing is a device that can print 3D object with different layer making it a solid 3d product. It consists of numerous numbers of layer which is compiled and form a whole object. Various fields use this technology, like for production of sample designs.

Firstly I made a 3D design in auto cad software. This is a prototype of a aquarium stand, an interior element design. 3D design in computer help us to understand the how the design will look but the 3D print help us to feel the design as we can see  how it will look in real form.

The auto cad 3d is then export as .3ds format so that it can be imported from 3D max software to render. The rendering is done mapping texture picture in it.

The file is then export as .STL format to open for 3D printing process with zprint software.

Set the unit to use like inch, meter and then scale it if required.

The 3d object can be edited with z edit if texture is required to be set through this software.

The steps were followed as instructed by the printing software to make sure that the printer is working properly and the printer is ready to print our object.

After everything is set, the print can be done and estimate time to finish is also given.

 

The object was very thin in some parts so some of its part was broken when they were taken out from printer. Some of the parts were fixed with glue (Z bond) and the final object was ready applying glue all over making it strong enough.

 

 

 

 

 

 

CNC turning (with G-code programming)

G-code is a common name for the programming language that drives NC(Numerical Control) and CNC(computer numerical controlled)machine tools. G-code is also the name of any word in a CNC program that begins with the letter G, and generally is a code telling the machine tool what type of action to perform, such as rapid move and controlled feed move in a straight line or arc.

NC Codes that are commonly used are:

G00     Rapid traverse; point-to-point

G01     Linear interpolation

G02     Circular interpolation arc CW

G03     Circular interpolation arc CCW

G90     Absolute dimension input

G91     Incremental dimension input

M01     Program stop

M02     End of program

M03     Spindle on CW

M05     Spindle off

M06     Tool change

N         Block number

F          Feed rate (usually in IPM)

S          Spindle speed

T          Tool selection

Firstly I draw a sketch for designing product with dimensions. The co-ordinate points are then found out to develop a NC code. The product I am using is cylindrical shape wood with size of 2” length and .5” diameter.

After writing the code, we can check the code through a software LATHE. The development of software has helped to simulate the product before taking it to real design. This gives us opportunity to modify the code as required.

Type the code in note pad and then copy it and paste it to lathe software screen.

The code need to be verify first. Press verify button and arrange verify program. In verify setting, arrange tool position. Here the initial tool position is at x .25z1.6 .
And type the length of stock 1.5″ with diameter .5″. Then press run to verify the program.

After it is verified, the code is paste in CNC base software to print the final product.

In the machine, the material is kept inserting .5″ and projecting stock 1.5″. Then the tip of tool is kept just above the object and the position of tool at z is noted which is kept in SET POSITION BOX  i.e z 1.4

The program is verified once again and then  the product can be sent for final cut.

Fused Deposition Modeling

Fused deposition modeling (FDM) is a technology used for modeling, prototyping, and production. FDM works on an additive principle by laying down material in layers. Acrylonitrile butadiene styrene (ABS) polymer is used to make the product.

The 3D object can be created with different software like Rhino, Auto cad and 3D-Max and the file should be exported with file extension .stl format. This design is created in Auto cad.

The estimated cost for this product is around $15 with the rate of ABS product as $5 per cubic inch.

Process for printing:

Firstly the computer should be turn on and then the FDM machine pressing the Start button to warm up the machine. The machine temperature for ABS material should be: modeling material -270, support material – 265 and envelope -70 centigrade. Open the STL extension file through software named insight and the typical setup for ABS plastic should be:

Do set up as following:

• Reorient as required thinking about how the support material will support the model. Generally, it should be rotated so that the support material and build time is minimal. Click STL ROTATE to reorient the 3d.
• Scale it as required to limit the size of prototype. Click STL units and scale. As I had designed the model in real scale of size ( 2.26 cubic inch) the size of 3d model was made of small size. So I didn’t need to rescale it.
• In upper left of the screen, there are different icons and they are required to press in sequence

First: press slice icon

Second: press generate support icon

Third: press toolpaths icon

Then press save icon to save toolpaths file

In the FDM machine:

• Arrange the foam placement as required
• Click auto shut off status
• The pause button is needed to be turn off so that FDM can receive the information from the computer.

Now the build icon can be pressed in insight screen:

• In the pack and download dialog box, the information regarding estimated model and support material to be used and total time estimate can be known.

In this project:

Model material used: 2.26 cubic inch

Support material used: 0.60 cubic inch

Total time estimate: 8hr 57min

Click the icon to send the job.

• Then press the pause button to turn it off so that FDM will be go through initialization routines and extruding support material and wipe the tips.
• Remove excess material from tips and reposition the tip to front left to build the model and place the tip just above the foam.
• Now press the pause button light

After the estimated time, the product is ready. The product comes with support material which need to be removed carefully.

• 

After removing the support material, the final product is ready.

3D Laser Scanner

Laser scanning and surface modeling

3D Laser Scanner is a device that scans 3D objects using laser rays. It scans numbers of faces of 3D object collecting data in computer software named Cydir.  The collected data can then be used to construct digital, three dimensional models useful for a wide variety of applications. Various fields use this technology, like production of industrial design and prototyping documentation of cultural artifacts.

Firstly I made a 3D object with gray clay to get scan. It’s a solid object which is a statue shape. It is a compulsion to turn on the scanner M-15 before turn on the computer. The 3D object is placed on turntable with extra gray clay so that it will not move while scanning. After that we can open the software named Cydir.

• Open the file “d” > classes > IDPT2802009
• Give a new name : xyz then press enter
• Click create and select
• Click the white triangle and replace “???” with 1
• 1 – is the first set of scan and follows with 2/3/4 for other sets of scans
• Click scan

Then in the Guee window

• Click open to change the settings of width of 3D object.
• Number of scans chosen was 16
• Now it’s ready for scan: click on scan
• After single set of scan is done, press merge

Now go to CyPie window

• Click on “ALL” for option Void
• Now by selecting the unwanted parts of scanned 3D and remove after pressing space bar to accept.
• Click on “ALL” for option Despike
• Then click on Auto Align
• And click on merge

Go to CyDir Window

Now it’s ready for next set of scan. The same process is repeated for scanning. I did 2 sets of scan keeping it vertical and horizontal position.

After all scanning set is done, it is required to align and merge sets of scan. Then click on Guess option for guessing to merge or we can manually align the sets. Then clicked on Refine options and then click on Final.

Now, go to Edit Mesh option in CyDir window clicking on white right triangle and double click on hires.ply. Then type “h” “f” to hide file and “v” for void.

type “h” “u” to unhide fill

type “.” “e” to save everything

then press enter

now press “shift F”, to fill all holes and press enter

Again press “shiftF”, “c” for final cleaning and press enter again

Press shift G for smoothness

Process for converting to 3D file>

click on convert mess and click white right triangle on the CyDir window

then select the file name and click convert ( convert with .3ds extension)

Go to Mtool>

Click sort faces and click on triangle to final output and give the name choosing file type. Now finally click convert on the Mtool.

After converting the file into .3ds extension, it can be rendered mapping texture and with environment background. We can use different program to render the object. For this project, I used 3D studio max.  Import .3ds file into max screen and map it with picture. The environment of different picture can be added to give background. The best view can be achieved using light and camera. The final picture can be saved as in jpeg format.

Laser Cutting

Laser Cutting is a new invention of technology used to cut material using laser.Laser cutting works by directing the output of a high power laser asdirected

through computer. The material melts, burns, vaporizes away, or is blown away by a jet of gas, leaving an edge with a high quality surface finish.

The process:

1. Create design with software CorelDraw, other software like Adobe Illustrator can also be used.
2. Choose different colors for applying different line properties.
3. For vector line, the outline color is chosen whereas for raster, fill color is used.

Firstly I tested the different speed and power properties using different color in rough material. It helped to understand the settings with raster and vector properties.

The note was taken for future reference.

Then the tested values were used for final product design. In this project, I have used all raster graphic with different power and speed values except for edge cutting frame.

Different colors were used with different color and property settings to create different cutting patterns in design. This is a design of size 6”x6”, the glass was easily available in lab. It’s a simple design with composition of rectangles with different cutting properties.

After getting design ready, send it to print then arranged the properties with following values:

The edge cutting vector line property is Power 100 with speed 0.6.

And other inner raster design properties are:

Power 100 with speed 50

Power 30 with speed 100

Power 10 with speed 5

Then send to print.

In laser cutter press green start button. In case of stopping the machine to cut, we can open the top cover of the laser cutter which will cancel the laser cutting process. The laser will beep when the cutting is completely done.

CNC MILLING

 

Step 1: Drawing design in Autocad

Step 2: Save as R12

 

Step 3: Import R12 file to Spectra cad software

Step 4:

>Select size of tool to drill

>Use operations like engrave, pock, countour and choose depth for each to drill

Step5: Save as .nc file to generate code

 

Step 6:Import nc file

Step 7:

>Verify the file to check it’s accuracy

>Run the program to print in CNC Mill machine

 

 

Final Product