Airforming - Adaptive Robotic Molding of Freeform Surfaces through Incremental Heat and Variable Pressure

Abstract

Advances in computational modelling and digital fabrication have created both the need and ability for novel strategies of bringing digitally modeled doubly curved surfaces into reality. In this paper, we introduce airforming as a non-contact and formwork-free method for fabricating digitally designed surfaces through the iterative robotic application of heat and air pressure, coupled with sensory feedback. The process lies somewhere between incremental metal fabrication and traditional vacuum forming of plastics. Airforming does not add or subtract material or use any mold or formwork materials that would typically be discarded as waste. Instead, airforming shapes a plastic sheet through the controlled spatial application of heat and the control of pressure and vacuum within an airtight chamber beneath the material. Through our research, we develop and test a method for airforming through 3D scanning and point cloud analysis, evolutionary physics simulation solvers, and robotic-aided actuation and control of heating and pressure systems. Different variations and analysis and workflow methods are explored. We demonstrate and posit potential future applications for the airforming method.