Digital Fab Lab

8/13/2019 Digital Fab Lab

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Digital Fab Lab

The newly renovated Digital Fabrication Lab (FABLab) at Taubman College leverages state-of-the-art industrial technology to

perform architectural fabrication research. It is one of few select academic institutions around the world utilizing robotic

automation to perform both subtractive and additive manufacturing processes. The technologies have existed in the aerospa

and automotive industries for some time, but have just recently infiltrated the architectural-fabrication industry.

The Fab Lab operates numerous computer-numerical controlled (CNC) machines, allowing students and faculty to work with

virtually any material.

Hardware

Two large 3 axis CNC routers process plywood or plastics, in addition to 3D surfacing wood and foam. A 3 axis abrasive wat

jet cutter can perform 2D cuts in any material up to 1" steel and 2" stone to five one thousandths of an inch.(005") tolerance.

smaller 3 axis bed mill can perform full 3D cuts in metals like aluminum and stainless steel.

The largest machine in the lab is the 7 axis Kuka Robot, with a 30'x10'x8' work volume. The robot is one of the largest in the

world at an architectural institution. The system has been laser calibrated to achieve accuracies approaching that of CNC

machines. The robot can load either a milling head for cutting wood and foam, or a water jet cutting nozzle for full 3D cutting

any material. The robot also utilizes a gripper for material forming or assembly processes.

The lab also makes use of four rapid prototyping machines for on-demand 3D printing of student models, and four laser cutte

for rapid production of sketch models from chip board or acrylic. Two of the rapid prototyping machines are located within the

architecture studios making it easier for students in studio to access the equipment 24-7.

The two new laser cutting systems are now installed in the west computer cluster on the third floor. These systems are

available for use by authorized users on a weekly signup basis.

A fully outfitted wood and metal shop supports the digital lab, allowing secondary processes such as bending and welding on

the digitally cut components.

3D Printing

The 3d printers are operated daily on-demand, students should just follow the procedures in the handbook for submitting you

file. If you need help from a Lab assistant, send an email to [email protected].

CNC Router Calendar

The 3-Axis CNC routers are accessible throughout the week. To schedule a time to use the CNC router, please check the CN

calender (link above). Available shifts are labeled 'OPEN.' To reserve your preferred open shift, please

email [email protected]. You will receive a prompt reply confirming your reservation.

Laser


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The laser cutters are available for use by authorized users 24/7. Laser Assistants are available various hours throughout the

week for assistance as needed. To contact one please email [email protected].

The Lab employs numerous assistants to help with the various operations in the lab, including the laser cutters, the CNC

router, and the 3d printers.

You can email the lab assistants at the following addresses.

[email protected]

[email protected]

[email protected]

The Digital Fab Lab Coordinator is available to help with CNC and rapid-prototyping projects, as well as other digital

troubleshooting. Please contact Wes McGee / 1223A A+A / [email protected].

A reference handbook has been prepared to orient users to the Fab Lab equipment, procedures, and operations. Users are

strongly encouraged to review these materials prior to setting up a project or contacting the lab coordinator.

Digital Fab Lab Handbook (PDF 115KB)

The Handbook outlines procedures for using the equipment in the lab. Please use the available 3D Printing Submission

Form (PDF 22KB).

In addition, the Art and Architecture Building houses the 7,000 square foot Building Technology Laboratory. The BTL is a

unique resource for class use in group assignments or demonstrations, individual investigation by students, or faculty and

research in teaching methods in the area of building technology.

Digital Fab Lab / Digifab Blog

The DigiFab Blog serves as an online gallery of ongoing work and research at the College relating to Digital Fabrication. Muc

of the work that is posted is a result of two courses, DigiFab I and DigiFab II. The goal of the DigiFab Blog is to assemble

relevant student and faculty projects together and make them accessible and visible to both those within and outside the

College.

DigiFab I

DigiFab I, taught by Maciej P. Kaczynski, exists primarily as a practical, hands-on introduction to material fabrication and

construction through the use of digital tools. More specifically, the course serves as a platform to familiarize students with

existing techniques of digital fabrication while fostering an environment dedicated to advanced material studies and

experimentation.

The tools are collaborators in the design process but are not necessarily the focus of the class. The course stresses the use

computer-driven tools as a means of material research and exploration. Proficiency with digital tools (and associated softwar


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must ultimately be demonstrated through finely crafted material explorations. The repetitious nature of the tools is exploited t

quickly produce and evaluate experiments and prototypes. Students spend the first half of the semester working individually

specifically guided projects to gain familiarity with the tools and various material palettes with an emphasis placed upon

tectonics and craft. Students will then form groups to propose and fabricate the final two projects. The scope and material

palette of the final project is self-guided. The fabrication of the projects requires students to master the software and hardwar

of the lab's most recently acquired CNC (computer numerically controlled) machinery: the Onsrud 3-axis router, Prototrak 3-

axis bed mill, and Flow dynamic 5-axis waterjet cutter.

DigiFab II

The course DigiFab II taught by Wesley McGee, functions as an evolving research lab for advanced fabrication techniques. A

wide range of computer controlled manufacturing tools are available in the digital fabrication lab. The newest machine, a 6 ax

industrial robot, serves as a multifunctional platform for both investigating new processes and producing full scale componen

The robot has a working volume roughly 30' x 10' x 6', and can change between various functional tools, including a milling

spindle, an abrasive water jet, and a gripper for assembly tasks. All of these tasks can be performed with high accuracy in 3d

space, at speeds much higher than normal CNC equipment.

Projects in the course include exercises to learn the workflows associated with fabricating with the robot, as well as

independent research projects designed by the students. An emphasis is placed on research which results in highly finished

full-scale installations. Prerequisites for the course include advanced 3d modeling skills in a program such as Rhino, Digital

Project, etc. and some experience with MasterCAM programming for the CNC router. Scripting experience is also beneficial

but is not required.

Digital Fab Lab / 3D Printers

3D printers, also known as 3D rapid-prototypers, are capable of taking digital geometry in the form of a stereolithographic file

(.stl) and producing small models. The necessary file can be produced from a variety of different 3D modeling software, such

as Rhino, 3D studio max, and Digital Project. Regardless of which software or 3D printer one is using, the file must be

"watertight," that is no open edge.

Here at Taubman College, we currently have four 3D printers available to students. Two print with plaster and two with ABS

plastic. While the plaster and plastic printers operate in different manners, the process of creating a file is identical. Yet, a ba

understanding of the limitations of each of these machines should be known before submitting a file.

Available Equipment

Plaster Printers


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The ZCorp 310 and 403 use plaster and a binding agent to create 3D models. Each has an

approximate building volume of 8" x 8" x 10". The length of time for a model to be printed ranges

from a few hours to 12+ hours. In addition, once done printing it needs to be excavated, cleaned

and if desired waxed. In comparison to ABS, plaster printing is a relatively quick procedure. The

403 is an older printer that has been with the college for some time and has slightly lower

resolution than the 310, which is a recent addition to the FabLab. While geometry has a great impact on the feasibility of a

print, a general rule-of-thumb is 1/8" minimum thickness. A waxer is available for plaster prints, since they otherwise tend to

very fragile.

ABS Plast ic Printers

The College currently has two ABS printers, which operate in the same manner, but have different

building volumes. The 768SST's building volume is 8"x8"x12", while the 1200es is slightly larger at

10" x 10" x 12". The ABS is stronger than the plaster and has some degree of flexibility. It therefore,

is capable of producing much thinner members than the plaster printers (as low as .040"). In

addition, both ABS printers offer a larger building volume than their plaster counterparts. The ABS

printers however take a substantially longer time to print and typically is more expensive than the

plaster printers. Print times can range from 12 hours up to 72 hours. The ABS printers operate differently than the plaster

printers, in that they print a support in addition to the model. This keeps the model from becoming unstable during the printin

process. After the print is complete, the structural support is removed by placing it in a chemical bath for around 12 hours.

Digital Fab Lab / Laser Cutters

The College operates four laser cutter systems. Two LaserCAMM systems are located in the A+AB

woodshop and are generally available for use on a sign-up basis during wordshop hours. Students

should consult Mark Krecik or Gerry Weston for orientation and assistance in using these two

laserCAMM machines. These lasers are more powerful than the third floor lasers and would be bet

at cutting thicker materials such as .25" acrylic or 3+ ply chipboard. More information is available

at: http://taubmancollege.umich.edu/lasercamm/

Additionally, two VLS 6.60 laser systems are located in the west computer lounge, on the 3rd floor. In order to use the VLS

6.60 systems you must go through an orientation with a Lab Assistant. These systems are available for use on a weekly sign

up basis. The sign up sheet will be posted Friday at 2:00pm for the following week. Students may sign up for two hours per

week. If no one signs up for a certain time, it is first come first serve. If it is 15 minutes past the allotted time, the slot is


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canceled and it is first come first serve until the next slot comes up. Once you have been trained and authorized to use the

laser, you will be able to log in to the system using your uniqname. The laser can only be activated by logging in to the PC

connected to it. You must log off when finished. Not logging off can result in the suspension of laser privileges.

The VLS laser systems have a working area of 32"x18". They are 50W lasers. The power and speed settings are controlled

a printer driver. The laser can be used to cut a wide variety of materials, including most natural materials. Chipboard up to 2

can be cut. Fabrics should only be cut if tested by a lab assistant; generally they must be dampened to cut without burning.

Acrylic plastics, both cast and extruded, can be cut. Decent quality can be obtained up to 1/8"; beyond this multiple passes a

necessary and quality is reduced. Polycarbonate(Lexan), copolyester, and PVC must not be cut. If the material is not listed

here, a lab assistant must be consulted before cutting.

Important: You must clean up after yourself. Do not place materials on top of the machine, it is not a worksurface! You

absolutely must not leave the machine unattended while cutting, no matter how experienced you are. If the machine is found

cutting unattended it will be shut down, and could result in revocation of laser priviledges for the logged in user. If a problem

occurs, or you observe anything out of the ordinary, send an email [email protected]

Digital Fab Lab / CNC Router

Procedure

1. Have an Idea

The first step is to have a good grasp of what you would like to do. What material are you considering? How big are you

planning? What end-product are you looking to get?

2. Talk with a Tech

It's a good idea to talk with a CNC router Lab Assistant early on. Their schedule is available online here. You can stop by

during a time listed unannounced, but it is recommended that you email them ([email protected]) ahead of time

letting them know you wish to meet. They may be busy with another student and unable. If you are already familiar with the

router and would like to ask specific question, then emailing should suffice.

3. Review CNC Basics

To further your understanding of how a CNC router works and what its limitations are, you should review the section titled CN

Basics. Review this may save time and material.

4. Complete Tutorials

Students should setup their own Mastercam file. Lab Assistants will review your file everytime before sending it to the router,

but they should not be depended upon for creating a proper Mastercam file. Since many students don't know


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mastercam, tutorials are being created. Once up, it is expected that the student has gone over the proper tutorials necessary

create their mastercam file. An honest attempt is expect of the student. If the student is unable to create the mastercam file o

their own, they may seek the help of a Lab Assistant.

5. Prepare Materials

There are a variety of materials that the router can cut. To review potential materials see the materials section. Material is no

to be stored in the router room, unless it is to be cut within 7 days. Material should be visibly labeled with a name and date. If

you are laminating material, such as MDF or ply, apply glue evenly and thoroughly. In addition, allow the glue 24hrs to dry. If

you are laminating foam, do not use wood glue or liquid nails. Instead, use gorilla glue.

6. Make Appointment

To make an appointment, check the CNC Calendar for available times. Once you have decided upon a time, email the Lab

Assistants at [email protected] specifying the time, material, and a short description your objective. They should

respond to you in a reasonable amount of time.

7. Arrive on Time and Cut

It is important to arrive on time. If you do not arrive on time, a Lab Assistant may take on another job or depart to do other

work. Given how busy it gets, especially towards the end of the semester, it is important to be punctual.

8. Clean Up

It is the students responsibility to clean up after the router job is complete. This means cleaning up the chips as well as

removing any remainder material.

Digital Fab Lab / CNC Mill

The CNC milling machine is of a 3 axis bed mill type. The machine can be run in a manual mode for traditional milling

operations. It has a user friendly programming language that allows 2/2.5 D programs to be written at the machine. For

complex 3D machining, mastercam is used for programming.

Materials

The machine can machine most metals including stainless steels, though the majority of work is done in aluminum. Small

plastic parts requiring a high accuracy can also be machined.

Access

The machine is only operated by trained Lab Assistants. If you have a job that requires the mill,

[email protected] to discuss the application. Complex 3D work will require the student learn Mastercam. Simpler

jobs may only require a drawing.


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Digital Fab Lab / CNC Waterjet

The 3 axis Water Jet cutting system is designed for cutting 2 dimensional profi les or shapes out of fl at sheet materials,

ranging from sheet metal to metal plate and plastics. For a description of the abrasive water jet process, go

to http://en.wikipedia.org/wiki/Water_jet_cutter. It is important to note that in all but a few cases, water jet systems cut

completely through a part, and do not have control over depth, like routers or milling machines.

Dimensional Limitations

The IFB4800 has a working range of 4'x 8' with around an 8" Z axis. This machine is equipped with state of the art dynamic

head technology, which elimintates the kerf taper common with waterjets, and can reliably produce parts with .005" tolerance

Materials

The machine can cut all metals and plastics, as well as rubber and wood. The material must be resistant to moisture, howev

so wood is rarely used.

Access

The machine is only operated by trained Lab Assistants. If you have a job that requires the waterjet,

[email protected] to discuss the application.

Digital Fab Lab / 7-Axis Robot

The 7 axis Robotic Workcell is a large format 6 axis articulated robotic arm mounted on a 10 m linear axis. The robotic syste

serves as a flexible, reconfigurable, motion control platform. A variety of tools can be mounted to the arm, including a high

speed router spindle and an abrasive waterjet cutting nozzle. In addition to machining processes, the arm can be reconfigure

to perform assembly work using a gripper.

Programming Workflow

Robotic programming requires additional steps not found in typical CNC programming operations. There are two primary

methods used to program this system. One uses the standard Mastercam X4 software, using 3-5 axis toolpaths. This is

augmented by a plugin called Robotmaster, which converts the toolpath to robotic motion instructions, and simulates the

toolpath on a 3d kinematic model of the TCAUP workcell. This offline simulation reduces the amount of physical testing need

to verify the program.

Dimensional Limitation

The Robotic system is composed of a Kuka KR100 HA L90 arm mounted on a K-1500-3 linear axis. The arm has a max reac

of 2.8m and a max payload of 90 Kg. The linear axis has a 10m travel. This allows the system to move between workcells,

allowing rapid conversion from one task to the next. Due to the complexity of the kinematics, there is no simple answer for ho


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large a workpiece can be; in general is must fall within the maximum limits. The workcell is pre-configured with a 4'x8' cutting

are for multiaxis waterjet and a 4'x8' cutting area for multiaxis routing.

Materials

In waterjet applications the robot can cut all metals and plastics, as well as rubber and wood. In routing applications, the robo

is limited to wood and foam materials. In general, robots do not possess the necessary rigidity to perform heavy cuts compar

to a gantry or bridge type router.

Access

In general, use of the robot is limited to specific dedicated course taught in the fabrication lab. As the number of trained user

increases, access to the machine will increase as well. The machine is only operated by trained Lab Assistants. If you have a

job that requires the robot, email [email protected] to discuss the application.

Digital Fab Lab / Digitizer

The Microscribe Digitizer allows one to create points in Rhino based off of a physical model. The working volume is

approximately 20" x 20" x 30".

Digitizing Points

To activate the digitizer within Rhino, use Tools > 3-D Digitizer > Connect then select MicroscribeDigitizerSupport. You will b

promted to enter an X and Y axis and specify a point in your Rhino file to match the origin of the digitized area. You can then

use the digitizer as you would a mouse.

Digital Fab Lab / Additional Tools

Additional tools and equipment available to student in the highbay include a hydralic press, various mig welders, a tig welder

large brake, a horizontal bandsaw, a drill press, a vertical panel saw, a large gantry and several grinders. An air compressor

can be accessed at different areas throughout the high bay.

Documents

Digital Fab Lab