Programming twist - Exploring the geometric affordances of aluminium through flexible robotic workflows

Abstract

This paper explores the geometric affordances of aluminium through flexible robotic workflows. The geometric abundance of the discussed workflows goes beyond what the state-of-the-art industrial metal forming processes offer, and is achieved with simpler means. Two fabrication methodologies, folding and pressing, were explored in order to convert flat, straight panels into twisted, 3-dimensional shapes. The design method for both fabrication strategies was based on physics simulation, where several geometrical constraints force a real time deformation while maintaining the properties of a developable strip. In the first fabrication approach, directionality of the rulings is first engraved into the material while the folding angle is controlled by the robotic setup with two gripping stations. The second fabrication approach refers to a forming process. This has been achieved by installing a wheel cutter on a small workshop hydraulic press and a robot feeding the material into the forming station. The design-to-production pipelines are automated and designed for a small payload robot that allows for a large variety of geometric possibilities. Fabrication challenges of both processes have been documented and assessed, while workflow optimization scenarios and future improvements are proposed in the outlook.