Catenary

The base geometry, resembling a flipped catenary, was intentionally designed with challenging twists and turns, introducing undercuts that added complexity to the manufacturing process. The aim was to create a piece that goes beyond conventional boundaries, requiring the precision of a robot arm for realization.

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The process involves the construction of a substantial volume of material using sheet stock, typically plywood or similar manufactured boards. These boards are CNC machined and stack laminated into blocks that approximate the shape of a larger form. Subsequently, the pieces undergo 3D robotic milling, and finishing.

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Nesting for CNC

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Each piece is precisely aligned and nested with the help of ‘Open Nest’ in grasshopper. The challenge lay in the unique twists of the design, making the nesting process a critical factor. The CNC operations involved a step-over of 15 millimeters and a tool diameter of 20, with four passes to achieve the desired finish.

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With Grasshopper guiding the slicing process, each piece was meticulously labeled for efficient assembly. Despite the challenging twists, our team successfully utilized nesting techniques to optimize the use of a single sheet of plywood.

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A five-axis robot, driven by the geometry generated in Grasshopper, was employed for the slicing process. The robot executed the intricate cuts, transforming the stacked pieces into a cohesive and captivating table. The robotic fabrication strategy involved a flat-end tool, emphasizing simplicity. The simulation phase proved crucial in preventing collisions, highlighting the significance of precise glue-up. Although the real-life outcome deviated slightly due to inherent inaccuracies, simulations served as invaluable testing grounds.