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A Physical Grammar

The shortcomings in design production with layered manufacturing software are limited in subdivision based on behavior and making.  This production system  translate a model into repetitious layers of material with little regard for model behavior, such as with structure or model balancing post manufacturing  or model size. A uniform set of layered material is inefficient and does not scale in ranges from the very small to building size. Most machines are limited in the maximum size of model manufacture; the maximum length for a common layered manufacturing device is less than 10 inches (25.8 cm) (Fig. 2a). Architects, however, would benefit from a variety of size models that can be manufactured from the same machine with software functions that subdivide a model into parts with attachments

Architects need descriptions that work with a variety of size machines from the very small to larger layered manufacturing machines, such as Contour Crafting. This need for diverse outcomes is best illustrated when an attempt is made to fabricate a variety of models. This research attempts to find an new description for layered manufacturing that can consider performance-based design factors as well as visual ones. Here a secondary computation is proposed that subdivides a model (initial shape) into objects that include an attachment strategy as part of the generative process.  Also a method to shape objects based on structural loading and mechanical strategies. Calculation and generation of these objects with features (such as attachments) occurs before the slicing algorithms found in layered manufacturing software. This paper introduces a production system as a schema that specifies information for materializing a design built of units. This system is defined as a physical design grammar used to transform a design model (surface model) into sets of scalable descriptions for production by layered manufacturing. These descriptions can be non-uniform models of the type shown in; these object-based descriptions differ in geometric description to satisfy most physical design constraints. In theory, the resulting geometry is scale-less; it can be used to build a small model or the full-scale building. The maximum size of each object represented as b in is limited by the machine size. The artifact itself, though, is limited in size by the number of parts, not the maximum length of b,as illustrated in the photos.


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