Principles of Computational Design and Additive Manufacturing Led by the Mediated Matter Group | MIT Media Lab E15-341 MAS.500 CAD/AM Module | TR 10:00 AM – 12:00 PM

Professors: Joseph Paradiso (joep@media.mit.edu) Neri Oxman (neri@mit.edu) TAs for CAD/FAB module: Christoph Bader (bader_ch@mit.edu) Veevee Cai (cail@mit.edu) Jorge Duro-Royo (j_duro@mit.edu) Chikara Inamura (inamura@mit.edu) Andrea Ling (asling@media.mit.edu) Daniel Lizardo (dlizardo@mit.edu) Julian Leland (jleland@mit.edu) Markus Kayser (m_kayser@mit.edu) Dominik Kolb (kolb@mit.edu) Sunanda Sharma (ssunanda@mit.edu) Rachel Smith (rssmith@mit.edu) Tim Tai (yjtai@mit.edu) Meghan Maupin (mmaupin@mit.edu) Nassia Inglessis (nassia.inglessis@network.rca.ac.uk) Overview The MAS.500 Principles of Computational Design and Additive Manufacturing module will explore ‘making’ through the lens of design, with a specific focus on designing for additive manufacturing. We will familiarize students with a selection of CAD software packages and computational design tools with which to create their own projects throughout the course of the module. Additionally, we will explore computational design and digital fabrication across multiple fields, including architecture, biology, and mechanical engineering. Students enrolled will gain insight into processes of digital and physical form finding, and acquire skills that will be applicable across scales and disciplines.

Session Outline:

S1 à 09/08 Intro, Course Overview, Documentation, Video, Photography Neri, Markus, (Jorge) Adobe, iMovie/MovieMaker/FCP, Photography/Video etc. S2 à 09/13 Modeling Design Julian, Jorge (Veevee) OnShape S3 à 09/15 Parametric Design Chikara, Daniel (Tim) Rhino, Grasshopper S4 à 09/20 Organic Modeling Christoph, Dominik Digital Sculpting, ZBrush S5 à 09/22 Design for Manufacturing Julian, Jorge, (Andrea) Processes, Scales and Bringing Digital Design to Physical Reality S6 à09/27 Mechanical Design Julian, Jorge, (Rachel/Nassia) Mechanical Engineering for Makers S7à 9/29 Material Design Josh, Sunanda Curing, polymer chemistry, Ashby

S8 à10/04 Additive Manufacturing and Casting Dominik, Daniel, (Meghan Maupin)

3D printing, finishing, molding, and materials (Reynold’s Advanced Materials will bring supplies), Printer Software Tutorials

SESSION 1 – 09/08/16 Introduction and Documentation

Quadcopter for video (DJI Phantom) Thermal image documentation example Gurus: Neri Oxman / Markus Kayser / Jorge Duro-Royo Description: Can you recall a powerful video of a design project? In this first lab, we will introduce the class and cover documentation tools to detail your design and fabrication work in a compelling manner. We will explore documentation in research, engineering, and life. Essential tools will be introduced such as graphic design software, photography concepts, and video production. Interesting examples such as quadcopter recording, SteadiCam stabilization, and thermal imaging will be discussed. There will be in-class exercises in graphics/video/photography.

Equipment required used (must download and install software beforehand): Please bring a laptop computer to class and have installed Adobe Creative Suite (free 30-day trial linked below, please have at least Illustrator and Photoshop trials installed) and a video editing software package (Final Cut Pro X has a 30-day free trial linked below, iMovie will also work or any other editing package). If you have a camera, please bring it and any cords required to transfer video from it to a computer (if you have a good cell phone camera, please bring the cable to transfer images/video off of it).

Relevant links: Adobe Trial (30 days): https://creative.adobe.com/plans Apple Final Cut Pro X: http://www.apple.com/final-cut-pro/trial/ Windows Movie Maker: http://windows.microsoft.com/en-us/windows-vis- ta/getting-started-with-windows-movie-maker Timelapse Assembler (Open Source): http://www.dayofthenewdan.com/ projects/time-lapse-assembler-1 Good general tutorial site for editing software: http://library.creativecow.net/ Basics of Final Cut Pro Xhttp://: http://www.izzyvideo.com/final-cut-pro-x-tutorial/ iMovie tutorials: http://www.izzyvideo.com/imovie-tutorial/ Windows Movie Maker tutorial: http://www.youtube.com/watch?v=JZXK68NS- 7gU Film + camera tips: http://www.film.queensu.ca/250/index_250.html Long exposure photography: http://www.youtube.com/watch?v=GY7i2ezphwc Illustrator: http://blog.spoongraphics.co.uk/articles/50-illustrator-tutorials-ev- ery-designer-should-see MIT Video Release Form (for all people shown in film): http://bit.ly/MSJVua Assignment description: Designing, shooting, and editing a 30 second video to convey the meaning of a supplied quote.

SESSION 2 – 09/13/16 Modeling Design: Onshape

Linear Stage Mechanical Design, Onshape Building Design, Digital Project, CATIA V5 Photo: Zaha Hadid Architects Gurus: Julian Leland / Jorge Duro / Veevee Cai Description: The Modeling Design session will briefly introduce computer-aided design (CAD) practices and strategies used across design disciplines, including animation, consumer product design, complex system development (aeronautic and automotive), and architectural practice. Students will then focus in-depth on the use of a specific engineering CAD package (Onshape), completing an in-class tutorial covering the basics of part layout, sketching, feature development, assembly creation, and manufacturing drawing. Software Used: Onshape (browser-based) - https://cad.onshape.com/

- Students must create an Onshape user account before class. Use of a free Onshape Educational account is recommended (https://www.onshape.com/edu).

Relevant Links: Students with no prior background with CAD tools are strongly recommended to complete the following tutorials before coming to class (https://www.onshape.com/learn/learn-cad):

- Section 1: Overview & Sketching – all videos, Basic Sketching exercise - Section 2: Basic Features – Extrude, Revolve - Section 3: Part Design – Starting A Design

Assignment description: Students will create a simple assembly around a preexisting model provided by instructors, containing both original and imported parts. Further information will be given in-class.

SESSION 3 – 09/15/16 Parametric Design: Rhino + Grasshopper

Diatom microorganisms displaying geometrical variation and feature differentiation, often a target of parametric design systems Gurus: Chikara Inamura / Daniel Lizardo / Tim Tai Description: This session will cover the foundations of parametric design and associative modeling. Students will learn how to embed parameters describing their designs, thereby generating associative modeling platforms that are generic, generative and flexible. Software used: (Must download and install beforehand) Rhinoceros 5 (windows only): http://www.rhino3d.com/download Grasshopper (Rhino plugin): http://www.grasshopper3d.com/page/download-1 Relevant links: http://www.rhino3d.com/tutorials http://designplaygrounds.com/ http://architectureecologies.com/ Assignment description: There will be an in-class assignment on parametric modeling.

SESSION 4 – 09/20/16 Organic Modeling: Digital Sculpting, ZBrush

Gurus: Christoph Bader / Dominik Kolb Description: Digital Sculpting allows the flexible manipulation of polygonal models, giving its users the ability to introduce features hard to achieve with traditional CAD tools usually geared towards the modeling of mechanical assemblies or products for mass-fabrication. Thus—and in contrast—digital sculpting enables the modeling of organic-looking artifacts, such as terrains, animals or characters. Compared to CAD modeling, utilizing parameterized surface descriptions, digital sculpting is still a relatively new method, having gained considerable popularity over the last few years. In this class we look at the basics of digital sculpting and organic modeling. Equipment: Students are required to bring a laptop with mouse or tablet with a trial version of Pixologic ZBrush pre-installed. Further instructions will be send before class begins.

Relevant Literature & Links: Winslow, V.L., 2009. Classic human anatomy: the artist's guide to form, function, and movement. Watson-Guptill Publications. ZBrush demo: https://pixologic.com/zbrush/trial/ Assignment: Students will be required to model an object with the tools introduced in this course and prepare it for 3D printing.

SESSION 5 – 09/22/16 Design for Manufacturing: Processes, Scales and Bringing Digital Design to Physical Reality

3DP sculpture (thermoplastic), B. Grossman 3DP column (glass), Mediated Matter Gurus: Julian Leland / Jorge Duro-Royo / Andrea Ling Description: The Design for Manufacturing session will introduce the steps required to take a designed object from concept to physical reality. Students will be introduced to the fundamentals of additive, subtractive and formative fabrication processes; walk through the basics of design for manufacturing (DFM) with 3D printing and laser cutting using an example project; and finally, demonstrate the diversity of form that seemingly simple fabrication processes can offer designers. Software used: Students are strongly recommended to follow along with the DFM tutorial in-class. They may use whatever CAD system they prefer, although part files will be provided in Onshape native format. Students should also download & install the following software packages: Cura: https://ultimaker.com/en/products/cura-software PreForm: http://formlabs.com/products/preform/ Relevant links: Students may find the following DFM tutorials useful: Ponoko Laser Cutting Tutorials: http://support.ponoko.com/hc/en-us/sections/204484428-Laser-Cutting-Tutorials-Tips Shapeways 3D Printing & Design Tutorials: http://www.shapeways.com/tutorials/ Assignment description: Students will select a single custom component that they have developed, perform DFM analysis on the component, make any required modifications to prepare for manufacture, and then create a machine-ready file appropriate for the process they are intending to use. Further information will be given in-class.

SESSION 6 – 09/27/16 Mechanical Design: Mechanical Engineering for Makers

Design Calculations à CAD Model à Finished Part Gurus: Julian Leland / Jorge Duro / Nassia Ingleiss Description: In this session, students will be introduced to the basics of mechanical engineering design. The session will be segmented into three parts. First, basic techniques for mechanical design ideation and refinement will be presented. The session will then cover basic principles for refining mechanical designs, including a review of fundamental principles for successful designs; design analysis techniques; a brief overview of common mechanical design components, such as machine structures, motion systems, and sensor systems; and finally, tips and tricks for improving design quality and reducing the designer’s effort. Finally, the session will review techniques for executing mechanical designs, with a particular focus on design techniques that facilitate rapid fabrication and design validation, and component sourcing. Software used: None Relevant links: The following links are not required reading for class, but are valuable design resources for any mechanical designer. Interested students may want to skim these resources before class, to get a sense of what information is available: Machinery’s Handbook, 27th Ed. (MIT ID required): https://app.knovel.com/web/toc.v/cid:kpMHEGMH0B/viewerType:toc/root_slug:machinerys-handbook-27th Alex Slocum’s FUNdaMENTALs of Design: http://pergatory.mit.edu/resources/FUNdaMENTALS.html Charles Guan’s How To Build Your Everything Really Really Fast: http://www.instructables.com/id/How-to-Build-your-Everything-Really-Really-Fast/ Assignment: Students will prepare a brief report reviewing the design of the custom system they have created in previous assignments. The report will describe the design intent and functional requirements of the system; identify critical areas of the design and propose analyses that could be used to verify system performance; and finally, source components and materials required to create the system.

MAS650 - 2-Part Assembly Design Sketch Pg. 3Wednesday, March 9, 2016 8:23 AM

Mediated Matter Page 3

SESSION 7 – 09/29/2016 Material Design: Making Materials That Expand What Can Be Designed and Fabricated

Bioengineered Soccer Ball, Jonathan Scholl Ice Feather, John O'Shea Metal Cross-section, AvizoGurus: Josh Van Zak / Sunanda Sharma Description: If you want to make materials that expand what's possible to design and fabricate, then this is the session for you. In this session, students will get a basic overview of the scientific and engineering principles behind material design and creation. In the first part of the session, general components of the material design process will be surveyed, focusing on desired performance metrics. and optical qualities. Subsequently, we will review various techniques for synthesizing new materials to perform in accordance with the designer's criteria. Here, students will get a helpful overview of basic material chemistry, physics, and mathematics with which to imbue materials with specific functions and properties. Finally, we will go over resources and iterative experimental techniques to test and optimize material performance and optical qualities, with an eye toward future applications in fashion, biomedical engineering, product design, architecture, and mechanical engineering. Equipment used: Just bring yourself and any questions relating to materials! Relevant links: A comprehensive list of useful links will be sent out two weeks prior to this session. Assignment description: No assignment, as this is the last class before the final assignment is due. However, it would help us make the most of your time if you were to skim through at least one resource from each category in the relevant links we will send you.

SESSION 8 – 10/04/16 Additive Manufacturing and Casting

Gurus: Dominik Kolb / Daniel Lizardo / Meghan Maupin Description: This session will be split in two parts with focus on 3D printing and casting. In the first half of the session, students will get a brief introduction to the range of machines and materials, available for 3D printing. We will take a look at the fields of application of additive manufacturing and its advantages and limitations compared to other fabrication methods. Students will be walked through the process of preparing a CAD design for 3D printing on some of the more common printers found in design/fabrication shops on campus, followed by a live printing demo. The second half of the session will focus on post processing 3D prints + casting and fabrication using digitally fabricated molds. Covered materials will include castable polyurethane and silicone, as well as finishing techniques for 3D printed models/molds. Specialists from Reynold’s Advanced Materials will be on-site to walk through basics of casting and finishing. Equipment: Students are required to bring a laptop with a pre-installed version of the 3D printing software for the Formlabs printer called “PreForm” and for the Makerbot printer called “Makerbot Desktop”.

Relevant Literature & Links: PreForm software: http://formlabs.com/support/software/install-preform-software/ MakerBot Desktop software: http://www.makerbot.com/desktop 3D printing introduction: https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/ Basic casting tips/guidelines: http://www.smooth-on.com/howto.php Reynolds Advanced Materials: http://www.reynoldsam.com/ Assignment description: This will be a workshop hands-on class with a 3D printing and casting demo.