Date: 2023.01-2023.05
Academic | Studio | Research By Design
Program: Material Agencies: Robotics & Design Lab
Instructor: Robert Stuart-Smith
TA: Hadi El Kebbi, Matthew White, Sophia O’Neill
Group work
Renhu(Franklin) Wu, Shunta Moriuchi, Yinglei(Amber) Chen, Sihan Li
The research paper detailing this project was presented at the 2023 ACADIA Conference
Academic | Studio | Research By Design
Program: Material Agencies: Robotics & Design Lab
Instructor: Robert Stuart-Smith
TA: Hadi El Kebbi, Matthew White, Sophia O’Neill
Group work
Renhu(Franklin) Wu, Shunta Moriuchi, Yinglei(Amber) Chen, Sihan Li
The research paper detailing this project was presented at the 2023 ACADIA Conference
1. Introduction
1.1 Established methods
Currently, there are four established methods for introducing variation in slip cast parts from the same mold.
1.2 Research Aim
Our research aims to create diverse cast shapes to produce geometric variations from a single mold, by integrating robotic motion and simulation into the slip casting process for enhanced flexibility, precision and efficiency.
Our research aims to create diverse cast shapes to produce geometric variations from a single mold, by integrating robotic motion and simulation into the slip casting process for enhanced flexibility, precision and efficiency.
2. Our Approach
2.1 Proposed Workflow
2.2 Feasibility Tests
Before implementing the robotic system, we performed small-scale manual partial-cast experiments using a custom jig to test the feasibility of our proposed partial casting methods.
2.3 Initial Robotic Test
Dynamic casting process through repeated robotic motion
3. Simulation Software
To solve the challenge of unpredictable slip movement in dynamic slip casting, we've created a simulation software.
The simulation program records the mold orientation throughout the casting process. By capturing the mold’s orientation, we can effectively simulate the continuous rotation of the mold during the dynamic casting process.
The simulation program records the mold orientation throughout the casting process. By capturing the mold’s orientation, we can effectively simulate the continuous rotation of the mold during the dynamic casting process.
The process involves calculating slip levels within the mold for various orientations using a binary search algorithm. It then identifies which mesh parts are affected by the slip and their durations. Finally, it generates a detailed result depicting the final appearance of the cast part, including specific thickness variations.
Traditional Method
Proposed Method
4. Proposed UI Design
Incorporating virtual reality (VR) technology into the design and fabrication process of bespoke slip casting has the potential to significantly enhance the user experience and expand the range of design possibilities. By enabling users to manipulate the virtual robotic arm’s tool calibration point (TCP) using VR controllers, they can gain real-time visual feedback on the appearance of the actual piece, allowing for more intuitive design adjustments and exploration of unique forms.
This proposed method, which combines VR technology with robotic slip casting, fosters a seamless integration between design and fabrication processes, encourages greater creativity and innovation, and enables users to better anticipate potential challenges in the fabrication process, such as slip shrinkage and surface tension issues. Ultimately, integrating VR technology into the bespoke slip casting process not only expands design possibilities but also has the potential to significantly improve the quality and adaptability of the final products.
5. Customed Robotic End-effector
To further fine tune our workflow, we designed and fabricated a larger mold and a custom end-effector with aluminum extrusions. The design integrates a series of CNC foam inserts that would hold various types of mold in different initial starting orientation while also allowing for ease of interchanging of the molds for different robotic routines.
Slip Injector: Necessity to Enhance Product Quality and Accuracy
Although the developed simulation was a simplification of the dynamic slip casting process and some misalignments
persist due to shrinkage during solidification and drying, which may necessitate further research.
persist due to shrinkage during solidification and drying, which may necessitate further research.
End-effector: Slip Injector
To address the decreasing slip inside the mold, we’ve designed a unique Arduino controlled slip injector that adds more slip as needed as each cycle of robotic routine is repeated. This helps maintain balance and ensure a smooth casting process while reducing the thin brittle edge condition. The design integrates an stepper motor that is controlled by robot’s i/o that actuates a syringe for precise slip volume injection and a LCD screen with a button system for easy adjustment of slip amount for different robotic routine.
To address the decreasing slip inside the mold, we’ve designed a unique Arduino controlled slip injector that adds more slip as needed as each cycle of robotic routine is repeated. This helps maintain balance and ensure a smooth casting process while reducing the thin brittle edge condition. The design integrates an stepper motor that is controlled by robot’s i/o that actuates a syringe for precise slip volume injection and a LCD screen with a button system for easy adjustment of slip amount for different robotic routine.
Plaster Mold Production
The plaster mold was fabricated using a 3D printed shell which liquid plaster was poured and got melted away with a heat gun after the mold has cured. The plaster mold is an 4-part mold with interchangeable lid at each node that allows for selection of injection point depending on the desired casted piece and initial starting position of the robotic routine.
The plaster mold was fabricated using a 3D printed shell which liquid plaster was poured and got melted away with a heat gun after the mold has cured. The plaster mold is an 4-part mold with interchangeable lid at each node that allows for selection of injection point depending on the desired casted piece and initial starting position of the robotic routine.
5. Prototype Fabrication
5.1 Geometric Design - Gird System
We conducted grid system studies using node-based geometry to explore geometric variations and their applications in architectural facades. By adjusting node sizes, we achieved diverse designs, refining scale and visual appeal. Node spacing and different configurations also played crucial roles in achieving desired effects. We successfully fabricated a full-scale mock-up to validate our findings.there are various node types and configurations to choose from, each offering distinct visual possibilities.
Pentagonal Tiling Grid was selected for fabrication.
We conducted grid system studies using node-based geometry to explore geometric variations and their applications in architectural facades. By adjusting node sizes, we achieved diverse designs, refining scale and visual appeal. Node spacing and different configurations also played crucial roles in achieving desired effects. We successfully fabricated a full-scale mock-up to validate our findings.there are various node types and configurations to choose from, each offering distinct visual possibilities.
Pentagonal Tiling Grid was selected for fabrication.
5.2 Fabrication
Prototype was designed for fabrication to fully test our extended research. The prototype consists of 28 pieces based on a tetrahedral grid system for it’s symmetrical nature and 4 mold variations for fabrication feasibility.
5.3 Assembly
