FREEFORM CONSTRUCTION DESIGN INTEGRATION AND PROCESS CONTROL

Integrating Design and Process Control for Freeform Construction

Richard Buswell, Alistair Gibb, Rupert Soar and Tony Thorpe

Loughborough University IMCRC

   BACKGROUND

One of the main challenges facing the development of Freeform Construction processes is the interface between the process technology and the design function.  In effect, there exists a gap between the processes being developed, and how architects and designers will output construction data derived from a CAD model, to the Freeform Construction machine.  Within the field of Rapid Manufacturing this is a long standing discussion which has resulted in the almost universal uptake of the .stl format (sometimes referred to as the stereolithography language).  It is not enough to export a 3D CAD model to a Rapid Manufacturing machine as 2D slices.  Sending 2D slices to a Rapid Manufacturing machine does not tell it what is solid and what is not, so part of the function of the .stl format is to calculate this so the Rapid Manufacturing machine knows what to build and what not to.  Freeform Construction machines also need slice data exported from a CAD model, but if we are to integrate different materials, services/channels/ducts, and data to allow us to build at different scales or resolution simultaneously, then we may need to look at this again.  The good news is that as this technology is in its infancy, we can begin to make the links to the architectural and structural design elements from scratch.  This may mean taking a closer look at STEP or its derivatives.  Either way, we need to work closely with the construction CAD software companies and the designers to look at what this will entail.

  OBJECTIVES

How suitable existing data protocols are, and how the integration of the design information into a 3D model can be done, are the principle aspects to this investigation. The concept of Freeform Fabrication, for producing the elements of construction or for building structures, introduces a significant departure from conventional construction processes. The work is currently addressing the following themes to:

  Investigate design and process control and identify the requirements for Freeform Construction applications.

  Identify the technological requirements and data formatting necessary to support Freeform Construction design and process control.

  Demonstrate the production of an artefact constructed using Freeform Fabrication using conventional construction CAD packages as the design tool.

  Develop a Freeform Construction network, disseminate technology, and engage the design industry to formulate further research proposals.

The project is driven by a combination of technology review and validation for construction through studies and interviews. Design process and process control are core to the investigation. Data formats and protocols and their suitability for Freeform Construction, are being evaluated. The process of generating freeform artefacts using industry standard CAD is being demonstrated and evaluated.

 Please click HERE for contact details.

Please click HERE for sponsor and collaborator details.

© 2005 Rupert Soar. All rights reserved.