3D Printing Architecture

Inhaltsverzeichnis

1. Frontmatter

2. 1. Introduction

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   This chapter examines how architecture is shifting as designers start to adopt additive manufacturing as a powerful fabrication method in full-scale built designs. Current and emerging trends, such as a search for formal and spatial complexity, the use of ornament, and the search for sustainability, are discussed. In addition, changes in the design workflows, where information from the construction phase is readily and effortlessly available at early design stages, are reviewed. Key applications in the construction industry being explored at the moment are presented. Finally, the ten projects by AirLab are introduced as case studies to illustrate the potential of advanced manufacturing technologies for architecture.

3. 2. Additive Manufacturing Technologies for Architecture

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   This chapter covers the existing and emerging 3D Printing technologies and their potential and limitations for architectural design. Aspects related to the cost of production, size limitations, speed and mass production, material properties, and environmental benefits are discussed. A selection of the most relevant printing technologies for architecture is analyzed in more detail, including direct concrete printing, fused deposition modeling, direct metal laser sintering, and binder jetting.

4. 3. Optimized Structures: AirMesh

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   This chapter describes the opportunities related to the application of additive manufacturing to the design and manufacturing of non-standard load-bearing structures, focusing on space frames. With 3D Printing, space frames design is not limited by standard components and standard fabrication methods, enabling optimized frames in which the frame topology and nodal joints are specialized for their specific stresses within the structure. Digital design approaches and workflows, including the overall form generation, element definition, and topology optimization are presented in detail. As a case study, the chapter presents an in-depth analysis of the design and manufacturing workflows for AirMesh, a stainless steel pavilion developed by AirLab.

5. 4. Architectural Ornament: Timescapes

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   This chapter analyzes how 3D Printing technologies enable complex geometry projects with an intricate ornamental quality. It speculates about the disciplinary motivations for formal search and the technical aspects such as detail resolution, build volume, speed, cost, and assembly of complex projects. AirLab’s built project Timescapes, a 113 m² pavilion, is analyzed in detail, demonstrating innovations in design, manufacturing, and assembly workflows, as well as the essential challenges and limitations of 3D Printing for freeform ornamental architecture.

6. 5. Architecture Meets Organic Matter: Sombra Verde and White Spaces

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   Digital tools deliver high levels of control over a project’s geometry and manufactured parts. Digital modeling, CNC control, in tandem with engineered materials such as polymers, plywood, and metal, ensures the fidelity of the physical product against the digital model. However, the dependence of current digital workflows on standardized materials excludes a range of natural materials that can otherwise offer valuable aesthetic and performative opportunities. This chapter examines how additive manufacturing opens new possibilities for unprocessed materials such as bamboo and raw timber. It proposes and reviews a design and manufacturing workflow, in which the specific properties of more irregular materials are digitized so that the specific information of each element is incorporated into the digital design process. 3D Printing becomes crucial, as specialized parts can be manufactured for the unique characteristics of the raw materials. Design workflows, problems, and benefits are presented through two AirLab’s built projects: White Spaces and Sombra Verde.

7. 6. Interfacing Printed and Standard: OH Platform, Metadata, and Makerspace

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   As 3D Printing finds its way into architecture and construction, how existing materials and building methods interface with new additive manufacturing processes becomes a central area of exploration. Through three built projects, this chapter explores how additive manufacturing can work synchronous with standard materials and existing manufacturing methods. It analyses transitions between printed and non-printed components and describes novel strategies of detail design, hybrid manufacturing processes, and assembly methods that required novel workflows for their materialization.

8. 7. Systems Integration: (ultra) Light Network

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   This chapter investigates the new opportunities for multi-functional parts provided by additive manufacturing in architecture. Building parts layer by layer, 3D Printing eliminates the geometric restrictions of molds or subtractive processes and delivers parts where complex internal cavities and channels are possible. In this way, prospects for integrating multiple technical systems, including structure, power, data, and fluid transmission within a single multi-functional printed part, become evident. This principle is demonstrated with the built project (ultra) Light Network, a light-art installation that embeds an electronic light system within a 3D-printed spaceframe.

9. 8. Real-time Costing: v-Mesh

   Carlos BAÑÓN, Félix RASPALL

   Abstract

   Cost estimation is a crucial dimension of architectural design. Typically, the accuracy in cost estimation progresses from ballpark figures and rules of thumb in early stages to precise quotations as construction starts. Additive manufacturing enables a new approach to project budgeting, as precise costing can appear very early in the design process and provide feedback to the designers when the project is still at a stage where changes are easy and inexpensive to implement. This chapter discusses the new, biunivocal relation between geometry and costing when 3D Printing is incorporated in the design process, and the influence of real-time costing brings to the decision-making process. AirLab’s project v-Mesh is presented as a case study.

10. 9. Assembly Strategies: AirTable

    Carlos BAÑÓN, Félix RASPALL

    Abstract

    Additive manufacturing enables the design and manufacturing of complex structures with multiple unique parts. While printed parts can be easily manufactured, the assembly of intricate projects still remains a challenging endeavor. This chapter discusses how 3D Printing gives way to custom connections and careful design of assembly sequences, including the systematic organization of the information, physical parts labeling, joinery strategies, and the creation of virtual assembly models. The project AirTable serves as a case study to demonstrate this approach through a built project.

11. 10. Outlook

    Carlos BAÑÓN, Félix RASPALL

    Abstract

    This chapter discusses ongoing and future directions of 3D Printing in architecture through a reflection on the topics presented in this book. It summarizes the key existing and emerging applications. It describes the new design workflows including structural modeling and optimization, custom connection design, system integration strategies, manufacturability assessment, and assembly planning. Finally, it concludes by discussing three upcoming topics in 3D Printing: artificial intelligence for 3D part design, large-scale printing, and computer-assisted assembly processes.