SFW - 4D Printing

Self Forming Wearable - 4D Printing

This research delves into the design and development of self-forming wearable technology, specifically a wristband. The wristband will be produced using 3D printing on pre-stretched fabric with TPU filament. Upon release, the model will adjust its shape over time, resulting in a composite 4D structure where the fourth dimension is time. This was accomplished through the application of three distinct methods – Karamba Stress Lines Technique 01, Paneling Tools Technique 02, Mean D Technique 03

Design objects exploration

Wrist Band - Concept

The Wristband design is minimalistic, user-friendly and can be easily adapted for 3D printing technology. It has been designed to fit comfortably on any individual, regardless of size and shape. The minimal design and feasibility made it the chosen concept to proceed with

Material

Material – Lycra

Cloth – Black

Stretch – Two-way and Four-way stretch

Properties - 80% Nylon 20% Lycra

3D Printing Frame

3D printing involves the use of two frames, designated as Frame A and Frame B. The dimensions of the frame are 28cm by 26cm, as depicted in the accompanying image. Frame A is placed on top of Frame B, with the fabric material sandwiched in between, as demonstrated in the subsequent slides

Place Frame B on the bottom. Place a piece of fabric larger than the frame on top of Frame B, making sure the fabric is evenly distributed and not stretched in any particular direction. Then, place Frame A on top of the fabric, aligning the corners of both frames correctly.

With the frames and fabric in place, stretch the fabric either 2-way or 4-way as required by the design. Secure the stretched fabric in place by placing clips in the center of all four sides, as well as two additional clips on each side of the center clip. Ensure that all three clips on each side are in line with the inner open square of the frame

Two Way Stretch

Mark a point on diagonal sides of Frame A by offsetting 7.5 cm both horizontally and vertically. Then stretch the fabric until the marked point reaches the inner corners of Frame A, achieving a 2-way stretch

Four Way Stretch

Mark two dotted lines on the fabric by offsetting 7.5 cm from the inner side of Frame A on both adjacent sides of the frame, forming an "L" shape on each side. Stretch the fabric until both the dotted lines meet the inner sides of Frame A, achieving a 4-way stretch.

Methods

Karamba Stress Lines

Technique 01

Using the Karamba plugin in Grasshopper, stress analysis of a 3D object can be conducted. The most realistic stress lines can then be selected and the object can be 3D printed in fabric

Paneling Tools

Technique 02

Transform the paneled pattern geometries into a three-dimensional shell by embossing them onto a pre-stretched membrane and mapping them onto the mean curvature analysis

Mean D

Technique 03

Mean D is a method that combines a star-based technique developed by David Jourdan and applies it to a 3D object using mean curvature analysis

David Jourdan’s

Technique 04

This approach is a direct application of an inverse design method used by David Jourdan, based on his research findings

Karamba Stress Lines Technique 01

The Karamba plugin in Grasshopper is a powerful tool that allows for the stress analysis of 3D objects. The plugin allows the user to conduct an analysis on the object, taking into account various loads and boundary conditions. This analysis can then be used to identify the most realistic stress lines of the object, and these lines can be used to 3D print the object in fabric.

Experiment 01

Code

Wb_ks_01

Process

Karamba

Thickness

0.5mm

Fabric Stretch

40% Four way

Filament

TPU 95A - Blue

Displacement

95%

Experiment 02

Code

Wb_ks_02

Process

Karamba

Thickness

2mm

Fabric Stretch

40% Four way

Filament

TPU 95A - White

Displacement

70%

Experiment 03

Code

Wb_ks_03

Process

Karamba

Thickness

1mm

Fabric Stretch

40% Four way

Filament

TPU 95A - White

Displacement

85%

Experiment 04

Code

Wb_ks_04

Process

Karamba

Thickness

1.5mm

Fabric Stretch

40% Four way

Filament

TPU 95A - White

Displacement

60%

Experiment 05

Code

Wb_ks_05

Process

Karamba

Thickness

2mm

Fabric Stretch

40% Four way

Filament

TPU 95A - White

Displacement

50%

Experiment 06

Code

Wb_ks_06

Process

Karamba

Thickness

1.5mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

15%

Experiment 07

Code

Wb_ks_07

Process

Karamba

Thickness

1.75mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

Paneling Tools Technique 02

The process of transforming paneled pattern geometries into a three-dimensional shell involves embossing them onto a pre-stretched membrane. This creates a physical representation of the pattern, which can then be mapped onto the mean curvature analysis. This approach allows for the creation of complex and unique 3D shapes, while also taking into account the structural integrity of the final product.

Experiment 01

Code

Wb_pt_01

Process

Paneling Tools

Thickness

1mm

Fabric Stretch

40% Four way

Filament

TPU 95A - White

Displacement

95%

Experiment 02

Code

Wb_pt_02

Process

Paneling Tools

Thickness

1mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

Mean D Technique 03

Mean D is a method that combines a star-based technique developed by David Jourdan and applies it to a 3D object using mean curvature analysis

Experiment 01

Code

Wb_md_01

Process

Mean D

Thickness

0.4 to 1mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

90%

Experiment 02

Code

Wb_md_02

Process

Mean D

Thickness

0.8 to 1.2mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

60%

Experiment 03

Code

Wb_md_03

Process

Mean D

Thickness

0.8 to 1.5mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

40%

Experiment 04

Code

Wb_md_04

Process

Mean D

Thickness

0.8 to 1.5mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

10%

David Jourdan’s Technique 04

This approach is a direct application of an inverse design method used by David Jourdan, based on his research findings

David Jourdan, Mélina Skouras, Etienne Vouga, and Adrien Bousseau. Computational Design of Self-Actuated Surfaces by Printing Plastic Ribbons on Stretched Fabric. Computer Graphics Forum 41, 2 (2022), 493–506.

Code

Wb_dj_01

Process

David Jourdan's

Thickness

0.5mm

Fabric Stretch

40% Two way

Filament

TPU 95A - White

Displacement

30%

Prototypes

3D Printing Process

Future Exploration - Custom Script

Mean D

MEAN D.pdf

By combining the star-based technique developed by David Jourdan and mean curvature analysis, the Mean D method was created. This script for Grasshopper was developed, which allows users to apply the Mean D method to any surface created in Rhino3D

Mean D [C]

MEAN D [C].pdf

Mean D [C] is a script that assists users in creating 4D printing wearables by utilizing a 3D surface object and mapping a desired 2D shape onto it. This script is designed to be used with Rhino 3D and the Grasshopper player

Findings and Conclusion

The product necessitated the stretching of the fabric in two directions (diagonally), which is a crucial discovery in the development of this product. This discovery also expedited the progress of other methods
The crucial importance of finding the perfect equilibrium between the tension of the material and the density of the filament cannot be overstated
Denser pattern with thickness less than 0.6mm finds difficulty in 3D printing
David Jordan’s technique 04 requires further experiments. According to our findings inclusion of border line can reduce the displacement further
Inspiration from Davind Jordan’s technique combining with mean curvature analysis resulted in Mean D technique
The authoring of Mean D technique resulted in creation of plugin, which can be utilized for further exploration

Team - Gokul Ramesh, Swatika Natarajan and Venkateshwara Prasath Ravichandran

Tutor - Asterios agkathidis

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