4.212

Design Fabrication Design, Computation and

Computer Controlled Devices

Prof. Larry Sass Department of Architecture and Planning

Design Fabrication is an introductory course in the field of advanced computing, prototyping and building fabrication. The class is focused on the relationship between design, various forms of computer modeling both explicite and generative and the physical representation of information using rapid prototyping devices.

The office of Gehry Partners, and Norman Foster have mastered computational techniques using CAD CAM technologies to construct buildings such as of the Guggenheim Museum in Bilbao, and the Swiss Re building in London. These offices use various methods of computer modeling to run computer controled devices (CNC Machines) at the end of the design process. In contrast this course will explore tools and techniques taken from these offices and current research projects using rapid prototyping and apply them to the new design office. The work will explore the idea of the design office built of computers and small rapid prototyping devices that simulate the CAD CAM process. Questions in the course will be focused how will these methods change the language of design and the current design process.

This course is taught in five phases starting with simple rapid prototyping using solid modeling software, and end with digitally mockuped building components fabricated from CAD files using CAD CAM devices in collaboration with Parametric modeling software. The course meets once a week with a lecture and a hands on session to following.

THE USE OF RAPID PROTOTYPING DEVICES IN DESIGN

1. Historical Background

2. Theoretical Framework

3. The Course

PALLADIO WORKSHOP

Past Courses

PALLADIO WORKSHOP 1997-2001

Course focused on digital representation of Palladio’s unbuilt villas

details.

1999 – Palladio Workshop, Students studied the façade of San Giorgio Maggiore. Students spent a lot of type studying Palladio’s construction

Past Courses

Study of Construction Details

Detail of a missing dentil from the façade of San Giorgio. It was said by the masons working on the reconstruction that the stone used to build the dentil was turned with its grains facing the wrong direction

Past Courses

Study of Palladio’s original drawings

drawings

Students spend a day in the Palladian archives reviewing Palladio’s original

Past Courses

COURSE PROJECT Complete the design for the unfinished Villa Porto in Molina

Only the eight columns of the Villa Porto remain. Once the design of the floor plan is found the remaining parts of the villa can be built from the construction rules.

DIGITAL MOCKUPS

Past Courses

DIGITAL MOCKUPS 2002

The course was a studying in digital fabrication and materials. Dennis Shelden of Gehry Associates and Mark Burry of RMIT with MIT created a class between two schools, studying one project.

Students conversing on line with Dennis Shelden who is on the television monitor.

Past Courses

CLASS TRIPS

During spring break we went to the experience Music Project and a quick visit to Frank gehry’s office

The experience Music Project in Seattle

Past Courses

FIELD STUDIES

Full scale detail study of the Stata Center

Frank Gehry reviewing a mockup

Past Courses GENERATIVE FABRICATION GENERATIVE DESIGN WORKSHOP

The course concentrated on the study of lighting design using generative techniques for design and rapid prototyping as a means of reflection

Student Presenting a model to Hugh Whitehead, Judit Kimpian and Francis Aishe at Foster’s office in London

Past Courses

Use of CAD to generate building Details and Connections

2003 – Class visit to the Swiss Re tower

LECTURES

Session A – Design and Fabricating in Solids

Session B – Curves and Complex Design Fabrication

Session C – Design with CAD CAM Fabrication

Session A Design and Fabricating in Solids September 8 – September 29

Lecture 1 September 8 INTRODUCTION TO DESIGN FABRICATION

Lecture 2 September 15 NUMERICALLY CONTROLLED

September 22 STUDENT HOLIDAY

Lecture 3 September 29 ASSEMBLIES

Session B Curves and Complex Design Fabrication October 6 – October 27

Lecture 4 October 6 DESIGNING WITH CURVED SURFACES & COMPLEX GEOMETRY

October 13 STUDENT HOLIDAY (COLUMBUS DAY)

Lecture 5 October 20 SCALING

Lecture 6 October 27 TOLERANCE

Session C Design with CAD CAM Fabrication November 3 – December 8

Lecture 7 November 3 PARAMETRIC DESIGN AND RAPID PROTOTYPING

November10 STUDENT HOLIDAY

Lecture 8

Lecture 9

November 17 DETAIL DESIGN AND CAD CAM FABRICATION

November 24 CONSTRUCTION METHODS FOR PAPERLESS ENVIROMENTS

December 8 STUDENT PRESENTATIONS

ASSIGNMENTS

Study of Space (1) Assignment 1a Laser Cutting Assignment 1b 3D Printing Assignment 1c ASSEMBLIES I

Building of Walls(2) Assignment2a Paper Cutting and Curves Assignment 2b Fuse Deposition Modeling Assignment 2c ASSEMBLIES II

Design of Details (3) Assignment3a Modella & CNC Miling Assignment3b Waterjet Cutting Assignment3c ASSEMBLIES III

FINAL ASSIGNMENT (4)

GRADING (Full participation in all aspects of the course) Attendance and participation in class 20%

Assignment #1 - 20%

Assignment #2- 20%

Assignment #3 - 20%

Assignment #4 - 20%

COURSE POLICIES 1) Students are expected to complete all 9 assignments to full completion for a grade 2) This semester will not support teams of students working on one assignment. 3) Incompletes are not accepted.

COURSE FEE $100 – Covers 9 Cubic Inches of Plaster for ZCORP MACHINE 6 Cubic Inches of ABS Plastic 4 Cubic Inches of High Density Foam

Due in Class Sept 15 *Does not cover the cost of Final Assignment or Metals

COURSE STRUCTURE

Course Website: http://stellar.mit.edu/S/course/4/fa03/4.212/

Office Hours: Larry Sass – Wednesday – Friday 1PM – 5PM

(By Appointment) Carlos Barrios: Wednesday – 9AM -12PM

Materials

Course Text: Inside Rhinoceros –

Cheng, Ron K. C. Onword Press

Weekly Readings

Course Organization

Lectures 9 Exercises 3 Assignments

1 Final Project Lectures and Assignments are posted on Stellar

(Tuesday @ 9AM) Recitations Monday – 11AM – 12:00PM

COURSE STRUCTURE

Computer Programs: Windows Based Software 1) Autocad or Your Favorite Program 2) Rhino 3) Catia

No Course Limit

Fabrication Times Will Be In Groups

Associated Groups Design Fabrication Group Center for Bits and Atoms

WHAT WILL YOU LEARN

Rapid Prototyping and CAD CAM

Design and Construction of Curved Surfaces

Design and Construction of Building Details

Exposure to Upcoming Technologies