Computational Design and Robotic Fabrication Lecture Notes

Vocabulary flashcards covering computational design theories, robotic assembly systems, structural analysis, and fiber composite manufacturing based on the lecture material.

Computational Design

The use of computation to develop an engineering design loop; it acts as an amplifier to processes like parametric modelling, optimization, and generative design.

Digital Design

The use of computer tools to define shapes.

Parametric Design

A design approach that describes and designs symbolically based on the use of parameters.

Algorithm

An ambiguous set of properly defined instructions that expects a defined set of inputs.

Optimization

The act, process, or methodology of making something as fully perfect, functional, or effective as possible.

Data Trees

Information divided into branches holding different data, allowing one branch to change via an algorithm while others remain constant.

Structural Optimization Categories

Consists of Sizing, Shape, and Topology optimization.

Brute Force Optimization

A method of trying a very large number of design combinations and picking the best one.

Heuristic Algorithms

Genetic or evolutionary algorithms where a spread of solutions is generated, keeping good ones and discarding bad ones; the good ones can be mixed.

Deterministic Optimization

A gradient-descent approach that makes logical steps using mathematical gradients to move directly towards an optimum.

Surrogate Modelling/AI

An AI system that learns to predict modal displacement based only on geometry, supports, and load inputs.

Discrete Element Assembly

The assembly of components on site or as pre-assemblies, exemplified by projects like the Stacked pavilion, Programmed wall, and Programmed column.

FEM (Finite Element Method)

A computational method used to obtain approximate solutions to engineering problems.

Stability in Discrete Element Assembly

A requirement where each construction step must be stable on its own, as temporary states may govern failure and stability is not guaranteed by the final geometry alone.

Vertical Load Stability Condition

A structure is stable if the projection of the combined center of mass falls within the contact forces area.

Lateral Load Stability Factors

Stability is governed by sliding or overturning mechanics, influenced by friction and mass distribution.

Mobile Manipulators

A robotic system combining a mobile base and a manipulator, offering a scalable workspace and multi-station workflow.

Drones/UAVs

Robotic systems with large workspaces and reach, characterized by low set-up costs but limited payload and safety constraints.

Industrial/Serial/Anthropomorphic Arm

Robots with high degrees of freedom (DOF) and orientation control used for spatial assembly and 3D milling, but limited by reach and lower stiffness at full extension.

Cable-Driven Parallel Robots

Robotic platforms with huge workspaces and high speeds using lightweight moving masses, though they require complex tension management and calibration.

Stop Point

A robot position approximation with high accuracy where the robot slows down at the target point.

Fly-by Point

A robot position approximation with lower accuracy where the robot maintains constant speed nearing the point.

Tool Center Point (TCP)

Defines where the tip of the end-effector is in relationship to the center of the flange of the robot.

Joint Space Interpolation

A robot motion type that occurs between two targets but may result in a non-linear path.

Linear Interpolation

A robot motion type between two targets that provides maximum precision and a straight movement path.

Shoulder Singularity

A robot singularity occurring when Axis 1 is aligned with the intersection of Axis 4, 5, and 6.

Elbow Singularity

A robot singularity occurring when the robot is at the limit of its work envelope.

Wrist Singularity

A robot singularity occurring when Axis 4 and 6 are parallel, making it impossible to determine their positions.

Filament Winding

A technique where fibers are continuously deposited to form a structural component, enabled by precise robotic placement and computational design.

Monolithic Structural System

A system where fibers form a single, integrated structural component without discrete elements.

Modular Structural System

A system of modular components that increases constructability and scalability but may reduce structural efficiency.

Coreless Robotic Winding

A process where a 6-axis robot places fibers on a metal frame or soft formwork without a solid internal core.

Composite

A material consisting of at least two immiscible components with different structures, such as reinforcing fibers in a matrix.

Fibre Paradox

The principle that brittle materials become drastically stronger and stiffer as the fiber diameter decreases.

Thermoplastic

A plastic material that can be reshaped via heating.

Thermoset

A rigid plastic material that cannot be reshaped after its initial set.

Classical Laminate Theory Assumptions

Includes perfect bonds between layers, homogeneous layers, plate state of stress, and adherence to Kirchhoff-Love assumptions.

Von Mises Criterion

A distortion energy criterion used to predict failure by calculating equivalent stress.

Rankine Criterion

A maximum normal stress criterion that predicts failure if maximum/minimum stress exceeds ultimate strengths.

Form Finding

The process of shaping an object according to loads (e.g., hanging models or soap models) to carry loads through compression or tension.

Kangaroo Solver

A tool used to find equilibrium shapes of flexible membranes under tension using mesh relaxation or hanging chain models.

Winding/Fibre Syntax

Describes the fibre pattern topology via repetition (number of layers) and the sequence of anchor point identifiers.

Winding Resolution

Relates to the number of rovings used in each repetition.

Syntax Shift ($k$)

Represents the number of anchor points that the winding syntax shifts between different frames.

Optimization Ingredients

The components of an optimization problem: Objective function, design variables, constraints, and state variables.

Topology Optimization (TO)

Optimization applied to a continuum based on finite elements to find the most efficient material layout.

Additive Manufacturing Constraints

Includes overhang/supportability (e.g., $45^{\circ}$ constraint), minimum feature size, build orientation, and thermal distortion.

CNC Milling Constraints

Includes tool accessibility (3-axis vs 5-axis) and minimum fillet radius based on the cutter radius.

3D Printing Bond Strength

The interface strength between concrete layers of different ages, affected by surface quality and moisture.