Rationalization of Molds For Complex Architectural Geometries

Today, architects can design complex 3D geometries using state of the art modelling software. Yet, the realization of these geometries is still limited by the capabilities and constraints of the fabrication machinery. The Computer Aided Design (CAD) platforms used to design the geometries cannot evaluate fabrication parameters such as feasibility and machining time. This makes architects dependent upon fabricator’s input for introducing fabrication considerations into their creative process.

To bridge this gap, we developed a near real time computational method for the analysis and evaluation of fabrication parameters for complex geometry molds. The method predicts the feasibility, material use, and machining time required for fabricating the molds. The predictions are highly efficient because they are based on the mathematical analysis of geometric properties and not on the machining simulations used in the industry. The method was developed on the Rhino/Grasshopper platform for evaluating computer-controlled mold fabrication techniques such as cutting and assembly of sheet materials, 3-5 Axis milling of volumetric material and robotic hot wire cutting.

The method was demonstrated to have as little as 10% error deviation from simulations performed by traditional Computer Aided Manufacturing (CAM) software. Its running time is typically under a second, a fraction of the time required to transfer the CAD geometry to CAM, set up the fabrication parameters and run a simulation. The graphic interface provides designers with a real time visual feedback about the feasibility of their design and allows them to adjust it accordingly. The numeric results can be used as target functions for automatic optimization routines aimed at improving the geometry in various aspects. Additionally, fabricators can use the rapid evaluation provided to arrive at quick, precise cost estimates of complex jobs and to fine-tune their fabrication strategies.