Semester Project - Material Systems
The semester-long project for this course consisted on three different modules: additive manufacturing, subtractive manufacturing, and automated assembly.
For the additive manufacturing module, the idea was to design an object that would be otherwise difficult to cast from a standard casting mold, since we were going to 3d print the formwork in PVA and then cast the object using rockite inside the PVA formwork, and finally dissolve the formwork in water.
My role in this module was to design and cast the object, and so modeled an irregular lattice by tessellating a cylinder with an angled cut.
Design + casting + dissolving formwork
For the subtractive module, we were given a block of maple to make a stand for the object.
We wanted the stand to interface with the cast object, so the stand was modeled using the top part that was cut off when truncating cylinder for the mold. Using Mastercam, I made the program to machine the maple into the stand.
I also used a 3D scanner and scanned our cast object to capture the imperfections from the casting process in our model. This did not give us any extra functionality, but it was a fun experiment.
3D scan + stand model + Cast object and stand.
For the automated assembly module, we were given a set of wooden blocks to make a backdrop for the cast object and the stand.
My partner designed the backdrop arrangement; we then worked on developing the grasshopper script in Rhino for ABB RobotStudio to assemble the backdrop with wooden bricks.
Diagram and final assembly
Worked alongside Ethan Bennet on this semester-long project for the course SCI 6387 Material Systems: Digital Production. A design engineering course at the Harvard Graduate School of Design.