Pedagogical Approach for Additive Manufacturing of Molds to Produce Topological Interlocking Assemblies

Abstract

With bespoke fabrication on one end and mass production on the other end of the fabrication spectrum, this paper focuses on custom repetitive manufacturing. It reviews the process and outcomes of a studio offered at Illinois School of Architecture. The objective of the studio was to enable students to design building components for assembly, followed by digital fabrication of the components. The pedagogical methodology employed a project-based learning (PBL) method in the first project, and a problem and project-based learning (PPBL) method for the second project. In the first project, students developed an understanding of precast elements as well as acquiring a set of skills in additive manufacturing (AM) and mold making by analyzing a built precast case study. In the second project, students were tasked with designing topological interlocking assemblies (TIA) while designing a reusable mold for casting the modules. Pedagogy encourages reflecting on past architectural projects by exploring the rationale and limitations of traditional production techniques, before rethinking design and production methods by using advanced building technologies. This manuscript explains the process and outcome of the second project. Among the challenges to be solved in the second project was 1- designing a block geometry with complex curvatures on all sides for mortarless assembly; 2- designing the assembly resulting from the design of the block and iterating while assessing the daylighting and structural performance of the assembly; 3- digital design and fabrication of a plastic mold for repeatable casting of the block geometry. The projects were assessed based on responding to these three challenges. The studio resulted in installations that were exhibited at the end- of semester showcasing students’ projects. The installations demonstrated a proof-of-concept for 3D printing plastics as a formwork for repeated casting of interlocking concrete blocks.