This week we started with topics on manufacturing using computerized laser cutting. Personally, I had already had experience working with this technology. My previous projects were much more related to technical representations, so my current approach focused on experimenting with the flexible capacity of materials that are not typically flexible, such as MDF. To achieve this, parameters were tested based on a pattern that could facilitate this process.
To start the project, we began with two parallel fields of knowledge. On one side, we have the machine we will be using, the Trotec Q500, with which we will conduct tests to determine the necessary power settings for MDF. On the other side, we need to develop strategies that allow us to make rigid elements more flexible. For this, we opted for intermittent cuts combined with tabs that enable bidirectional articulation of the surfaces.
The Trotec Q500 cutter is operated using the company's proprietary software, JobControl, where we import plotted CAD files. In this software, laser power and speed are assigned to each operation based on the line color in the file.
For the next stage, I had to research solid development methods. Based on my knowledge of Grasshopper, I proceeded to install a plugin called Ivy, which allows me to find the development shape for meshes. This helped me establish the foundation for operating folds.
Week 2 will be dedicated to developing the G-code for the first exercises of The Machine That Cried. To achieve this, the following workflow will be implemented, starting with an AI-generated image prompt and ending with a text file containing the three-dimensional coordinates of the image.
1. The CAM laser cutting machine was used to conduct initial tests on the required cutting thicknesses to achieve a precise and press-fit connection between different materials (2mm model cardboard and 3mm and 4mm acrylic). It was discovered that the cut must be at least 0.2mm smaller to properly fit the intended material.
2. In the next step, a comparison was made between the required sizes to insert one cut section into another using tabs in MDF. This operation was carried out on the Trotec Q500 machine.
3. A guide of suggested laser-cut joints was collected, and all models were replicated, though not all proved functional. Innovations were also made, including a puzzle-piece-style joint by strategically removing material to create a proper fit.
4.Finally, the last test explores possible iterations based on flexion patterns applied to MDF, giving it the ability to unfold or form new shapes. The parameters considered were line spacing, line length, and the number of lines.
5. An algorithm was developed in Grasshopper to generate the initial unfolding of any convex mesh, allowing for the establishment of joint and folding types for the project. This was achieved using the Ivy plugin, which enables the identification of mesh triangles that can be folded and articulated based on the angles they form with each other.
6. Two types of folds were designed: joint folds and flexion folds. For the flexion folds, the naked edges of the mesh were identified, and offsets were created on both sides. These new lines were then segmented and scaled to generate an interlined pattern, mimicking the tests developed in the group exercise. Additionally, a chamfering system was used on the corners to prevent the material from colliding with itself during the folding process.
7. The next type of joint is designed based on the insights gained from the kerf tests for assemblies. Male and female interlocks are used, with a 0.4mm difference to allow for a press-fit connection, reinforcing the structure of the solid.
8. Next, material tests were conducted using MDF and cardboard to evaluate their behavior. The MDF test aimed to create a tower inspired by the Urbach Tower, while the cardboard test focused on a simple triangulated sphere..