Computational Fabrication: From Virtual to Real. Wojciech Matusik Computational Fabrication Group Massachussetts Institute of Technology

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1 Computational Fabrication: From Virtual to Real Wojciech Matusik Computational Fabrication Group Massachussetts Institute of Technology 1

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5 What Is 3D Printing Used For? 5

6 Other 1% Functional Parts 28% Prototyping, Presentation, Education 44% Manufacturing 27% 6

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14 Hobbyists, Makers, Prosumers 14

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18 Game Changers 18

19 3D Printing Services 19

20 Inexpensive 3D Printers OBJET Connex $250K MakerBot Replicator 2 ~$2K More units sold per month than OBJET Connex ever 20

21 Lessons from the Past Mainframe Personal Computer 21

22 State of the Art of Multi-Material Fabrication 22

23 Multi-Material 3D Printing 23

24 Multi-Material 3D Printing 24

25 Multi-Material 3D Printing 25

26 Multi-Material 3D Printers 26

27 0.5 m Large Build Volume 1 m 27

28 Large Material Library Courtesy of Stratasys 28

29 High-Resolution: 600 DPI Courtesy of Stratasys 29

30 Recent Research Results BSSDRF [Hašan 2010] Deformation [Bickel 2010] Co-Continuous Polymers [Wang 2011] FGM Prototyping [Oxman 2011] Tissue Constructs [Xu 2012] Tough Composites [Dimas 2013] Actuated Characters [Skouras 2013] Lenticulars [Tompkin 2013] Printed Optics [Willis 2013] 30

31 Current Industry Use 31

32 One Material Per Part Courtesy of Studio Fathom 32

33 Why One Material Per Part? Traditional constraints of manufacturing Lack of design tools Lack of scalable software architectures 33

34 Improve Specification Methods f Direct Specification Functional Specification 34

35 Improve Specification Methods f Direct Specification Functional Specification 35

36 Direct Specification Challenges Giga voxels/inch 3, Tera voxels/foot 3 Continuous gradation between materials Reusable material definitions Resolution and printer independence 36

37 OpenFab Programmable and Scalable Fabrication Pipeline 37

38 OpenFab Inspired by rendering pipelines Fixed stages and programmable stages Procedural surface and material definitions Resolution independence Streaming architecture 38

39 The OpenFab Programming Model 39

40 input tessellate surface stage voxelize volume stage dither output 40

41 input tessellate surface stage voxelize volume stage dither output 41

42 input tessellate surface stage voxelize volume stage dither output Shapes (boundary representation) Fablets Resources Textures Materials 42

43 input tessellate surface stage voxelize volume stage dither output 43

44 input tessellate surface stage voxelize volume stage dither output 44

45 input tessellate surface stage voxelize volume stage dither output 45

46 input tessellate surface stage voxelize volume stage dither output 46

47 input tessellate surface stage voxelize volume stage dither output 1 Voxel 50% A 25% B 25% C 47

48 input tessellate surface stage voxelize volume stage dither output 1 Voxel 50% A 25% B 25% C 48

49 input tessellate surface stage voxelize volume stage dither output A A B C 4 Voxels 49

50 Results 50

51 Material Decoupling 51

52 Material Decoupling 52

53 Material Decoupling 53

54 Procedural Surfaces 54

55 Procedural Volumes 55

56 Procedural Volumes 56

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61 OpenFab Summary Scalable and programmable pipeline for direct specification New programming model Domain-specific language 61

62 Improve Specification Methods f OpenFab Direct Specification Spec2Fab Functional Specification 62

63 Functional Specification Spec2Fab Translation f Functional Specification Printable Object 63

64 Spec2Fab Translation Assign Material Simulate Compare to Goal Good? Print Goal 64

65 Spec2Fab Translation Assign Material Simulate Compare to Goal Simulation Good? Print Goal 65

66 Spec2Fab Translation Assign Material Simulate Compare to Goal Simulation Good? Print Goal 66

67 Naïve Spec2Fab Translation Try all per-voxel material combinations Number of combinations 2 inch cube at 300 dpi 3 materials 3 (6003) = Monstrosity 67

68 Naïve Spec2Fab Translation Assign Material Simulate Compare to Goal Good? Print 68

69 Spec2Fab Translation Reduced Parameters Simulate Optimization Compare to Goal 69

70 Common Components Reduced Parameters Simulate Optimization Compare to goal Reducer Tree Tuner Network 70

71 Results 71

72 Spec2Fab for Texture Input Shape Stratum Column Material Material Material Material Goal Tuner Tuner Tuner Print 72

73 Spec2Fab for Translucent Materials Input Shape Stratum Column Material Goal Material Material Material Print Tuner Tuner Tuner 73

74 Spec2Fab for Complex Lenses Input Shape Column Goal Material Material Plane Material Plane Material Plane Tuner Tuner Tuner Print 74

75 Spec2Fab for Deformation Input Shape Goal: deformation Tuner Stratum Voxel Material Material Material Print 75

76 Spec2Fab for Deformation and Texture Input Shape Goal: deformation Tuner Stratum Texture Voxel Goal: texture Material Material Material Print 76

77 Spec2Fab Summary Unified model for functional specification and translation Modular, extensible, geometry independent, device independent 77

78 Abstraction for Fabrication Functional Specification Direct Specification Hardware/Materials 78

79 Abstraction for Fabrication Applications/Interactive Design Functional Specification Direct Specification Hardware/Materials 79

80 Computational Design of Mechanical Characters 80

81 Automata: self-operating machines or robots Sisyphus by D. Johnson 81

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87 Library of Mechanisms 87

88 Parameterized Mechanisms 88

89 Parameterized Mechanisms 89

90 Parameterized Mechanisms 90

91 Parameterized Mechanisms 91

92 Sparse Database of Representative Motions 92

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94 Phase Offset Velocity Profile Timing Control 94

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96 Results 96

97 Fabrication 97

98 Pushing Man 98

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101 Limitations: Kinematic Design 101

102 Design Motion Summary An interactive system based on A library of parameterized mechanisms A database of precomputed motions An intuitive user interface Outcome: novice-users can design complex automata 102

103 How to Design More Complex Things? 103

104 How to Design More Complex Things? 104

105 Design and Fabrication from Examples 105

106 Design Database 106

107 Real Designs are Complex 107

108 Our Designs can be Manufactured 108

109 Our Designs are Parameterized 109

110 Interactive Modelling Tool 110

111 Interactive Modelling Tool 111

112 Interactive Modelling Tool 112

113 Connecting Components 113

114 Articulated Models 114

115 Connectors and Support Structures 115

116 Connectors and Support Structures 116

117 Physics Simulation 117

118 Interactive Modelling Session 118

119 Interactive Modelling Session 119

120 Abstraction for Fabrication Applications/Interactive Design Functional Specification Direct Specification Hardware/Materials 120

121 Bridging the Gap between Virtual and Real User Input Output Devices 121

122 Thank You. 122