For the creation of the CAD files for the printed frame we used a combination of Autodesk Fusion 360, Rhino and Grasshopper. The frame was modelled first in Fusion 360 and then imported into Rhino to map networks of splines onto the surface using grasshopper. The reason we used this work flow was that it gave us a lot of form freedom and control. Allowing us to create complex but parametric CAD models that we could adjust and tweak as the project continued without a huge amount of manual corrections if something changed.This example illustrates our approach, 2D splines are projected onto the input geometry (A 3D Sphere). This is a relatively simple approach but again allowed us to have much more control over the splines than other more complex methods we tried. The resulting curves lay precisely on the input surface and if 2 curves intersect, we can be sure that this intersection is directly on the surface. The connection pieces where also modelled in Rhino to troubleshoot any issues with tolerances and placement with the frame.
The bike parts were bought last week, so more accurate dimensioning is now possible. We’ve had some emails going back and forth with Filippo, who is giving us suggestions and advise on how to improve our design and make it (more) printable. In general he seemed quite content and thinks we can probably print it in one go. This was good to hear! We’re looking forward to going back to Amsterdam this week and talking to the team. Also we are still busy with the wooden tables for MX3D, and hoping to get them to them by Wednesday, on time for their grand opening!
This first designing week proved to be rather tough for us. We’ve decided that by this week Thursday afternoon we want to have a well-worked out first design to send to Filippo so we can get some feedback on it. We have little time and are finding it hard to communicate our ideas. We all have different educational backgrounds and different ideas on what we want and think is accomplishable. We started off by brainstorming about several themes and construction aspects that we would like to incorporate into the design. In the end we narrowed down the options drastically and agreed that ‘less would be more’. Most of us are working on the design, in particular Harry is turning out to be our Grasshoppper-guy. Sjoerd and Joost are working on assembling bike parts, that we can attach onto the frame to have a complete bike in the end, these are important design parameters. For the design we’ve mainly been sketching, using CAD models and using plasticine.
For the design of the splines we had two different ideas. One was to make it more organic-like and the other to make the splines look more like polygonal shapes. It was important to make a decision for this, as developing two individual models for this would be too time consuming. In the end we chose the organic splines, but we were happy with either. In Joosts’ words: ‘It’s like having to choose between your mother and your father’.
Monday afternoon we visited MX3D at the Laarman Labs in Amsterdam. Everyone’s eyes were wide open when we walked into the meeting room and saw designs such as the Bone chair, the Maker chair, Heatwave radiator and all sorts of other cool experimental test shapes and objects.
We had a good conversation with Filippo and Jakob, from the MX3D team. They gave us a lot of insight into the possibilities and limitations of the robot arm. Also they mentioned they have tackled some of the limitations but are still willing to run some tests, so perhaps we can incorporate that in our designs for the bicycle frame. We discussed the overall planning, and it came down to: this week making a design, next week work on printing strategy and solving problems and then the last week of October we will have a week with the robot to print. This is a tight schedule but we hope to get a result in the end.
Filippo gave us a little tour of the Laarman Labs. This was very cool. Almost every object you see there you cannot help but wonder how it was made. The tour ended with the Dragon bench, which may have been a little disappointing in size but definitely lived up to the rest of the expectations. It was inspiring to see.
We had a great day in Amsterdam. The robot can do a lot and Filippo and Jakob seemed willing to help us out if we run into problems with the programming. We saw some very cool stuff at the Laarman Labs and left Amsterdam with a very content feeling and looking forward to starting with the designs.
The MX3D office does not yet have furniture in it. We wanted to make some furniture, starting with desks/tables. Ten sheets of 18mm plywood were ordered for us to use. We got some CAD drawings for a table from http://opendesk.cc/ and tried to use the CNC milling machine to make it. Here we ran into some trouble, seeing as the machine doesn’t work well with 2D CAD drawings. The people from the PMB asked us to rebuild the drawings into a solid model in Solidworks. So we did.
But even now with the solid parts the machine still wouldn’t work. The problem is with the driver software. We contacted a student from the TUDelft who is currently involved in one of the dreamteams. He is known to use different driver software for the CNC milling machine that copes better with the design of our table. He and an employee of the PMB will be working on it as soon as they can.
On Friday the second of October we visited MX3D at the NSDM wharf to introduce ourselves and take a look around. Their office is currently under construction, and we are hoping to help out by making some tables for them.The official opening of their new location is on the 16th of October. One of the co-founders, Tim Geurtjens, gave us a tour and showed us some of the capabilities of their machine. We got to see the bridge prototype that is featured in their promotional video, and which is the first project they worked on.
link to promo video MX3D: https://www.youtube.com/watch?v=pZNTzkAR1Ho
A Student of the Aerospace Engineering department here at TU Delft. He just got his motorbike license and enjoys building all kinds of things in his free time, for example he built a fixed gear in the past.
Ainoa Areso Rossi
Studies Civil Engineering at the TU Delft. She is spanish and italian but has lived her whole life in the netherlands. At civil she has learned theory about materials and structures and hopes to be able to put this into practice with this project.
Stef de Groot
He is an Industrial Design Engineering student at TU Delft and in his free time designs 3d printed models such as bicycles. He has an interest in applying new techniques to existing products.
A student at the Royal Institute of Technology in Melbourne at the faculty of Industrial Design. He is on an exchange and has lots of experience using CAD/CAM. He is interested in exploring the applications and boundaries of additive manufacturing.
Sjoerd van de Velde
He is a student at Mechanical Engineering at the TU Delft. He’s a real handy man, during the summer he works at an open air opera as a stage builder and owns an old-timer camper van. He also has a lot of experience with building prototypes and because of his background in mechanical engineering he has an affinity with metal and mechanical products.
Welcome to the 2015 Wire and Arc Additive Manufacturing Web Blog. Through this web blog we will keep you up to date on our project.
At the end of last week we had our first meeting with our project leader: Jouke Verlinden. He briefly explained about the possibilities this project has to offer. The scope of this project is to explore the possibilities or applications of the recent breakthroughs in Wire and Arc Additive Manufacturing and to try to build other type of objects or structures that can be manufactured using this technique. Also, Jouke showed us the RepRap which last years group built. We hope to get it up and running by the end of this week so we can do some tests with it.
After the meeting we brainstormed about what we wanted to build and everyone was very enthusiastic about a bicycle frame!
At the moment, the dragon bench is being manufactured at Laarman Labs (using WAAM). We hope to be able to visit the Laaramn Labs this week to get a look at how the machines are operated and to talk to the people working them. We want to learn how the machine works and about the limitations it has. This will help us to produce a first design for our bicycle frame.
The location of the WAAM robots we will be using is in Amsterdam, at the mx3D Lab at NDSM Werf fabriek. The place where we will be working in Amsterdam has no furniture, so this first week we have been developing CAD models to CNC mill our own wooden desk. We have done this using some initial designs from the opendesk website. We have managed to produce some smaller scale prototypes using the laser cutter. These were a great success!