We study assemblies of convex rigid blocks regularly arranged to approximate a given freeform surface. Our designs rely solely on the geometric arrangement of blocks to form a stable assembly, neither requiring explicit connectors or complex joints, nor relying on friction between blocks. The convexity of the blocks simplifies fabrication, as they can be easily cut from different materials such as stone, wood, or foam. However, designing stable assemblies is challenging, since adjacent pairs of blocks are restricted in their relative motion only in the direction orthogonal to a single common planar interface surface. We show that despite this weak interaction, structurally stable, and in some cases, globally interlocking assemblies can be found for a variety of freeform designs. Our optimization algorithm is based on a theoretical link between static equilibrium conditions and a geometric, global interlocking property of the assembly---that an assembly is globally interlocking if and only if the equilibrium conditions are satisfied for arbitrary external forces and torques. Inspired by this connection, we define a measure of stability that spans from single-load equilibrium to global interlocking, motivated by tilt analysis experiments used in structural engineering. We use this measure to optimize the geometry of blocks to achieve a static equilibrium for a maximal cone of directions, as opposed to considering only self-load scenarios with a single gravity direction. In the limit, this optimization can achieve globally interlocking structures. We show how different geometric patterns give rise to a variety of design options and validate our results with physical prototypes.
We present X-shells , a new class of deployable structures formed by an ensemble of elastically deforming beams coupled through rotational joints. An X-shell can be assembled conveniently in a flat configuration from standard elastic beam elements and then deployed through force actuation into the desired 3D target state. During deployment, the coupling imposed by the joints will force the beams to twist and buckle out of plane to maintain a state of static equilibrium. This complex interaction of discrete joints and continuously deforming beams allows interesting 3D forms to emerge. Simulating X-shells is challenging, however, due to unstable equilibria at the onset of beam buckling. We propose an optimization-based simulation framework building on a discrete rod model that robustly handles such difficult scenarios by analyzing and appropriately modifying the elastic energy Hessian. This real-time simulation method forms the basis of a computational design tool for X-shells that enables interactive design space exploration by varying and optimizing design parameters to achieve a specific design intent. We jointly optimize the assembly state and the deployed configuration to ensure the geometric and structural integrity of the deployable X-shell. Once a design is finalized, we also optimize for a sparse distribution of actuation forces to efficiently deploy it from its flat assembly state to its 3D target state. We demonstrate the effectiveness of our design approach with a number of design studies that highlight the richness of the X-shell design space, enabling new forms not possible with existing approaches. We validate our computational model with several physical prototypes that show excellent agreement with the optimized digital models.
This supplemental document provides more details on the implementation aspects of our numerical solvers (Section 1) as well as all the derivatives needed for the optimization (Section 2). Equation numbers below reference equations in the main paper (except for those prefixed by "A").
No abstract
Basket weaving is a traditional craft for creating curved surfaces as an interwoven array of thin, flexible, and initially straight ribbons. The three-dimensional shape of a woven structure emerges through a complex interplay of the elastic bending behavior of the ribbons and the contact forces at their crossings. Curvature can be injected by carefully placing topological singularities in the otherwise regular weaving pattern. However, shape control through topology is highly non-trivial and inherently discrete, which severely limits the range of attainable woven geometries. Here, we demonstrate how to construct arbitrary smooth free-form surface geometries by weaving carefully optimized curved ribbons. We present an optimization-based approach to solving the inverse design problem for such woven structures. Our algorithm computes the ribbons' planar geometry such that their interwoven assembly closely approximates a given target design surface in equilibrium. We systematically validate our approach through a series of physical prototypes to show a broad range of new woven geometries that is not achievable by existing methods. We anticipate our computational approach to significantly enhance the capabilities for the design of new woven structures. Facilitated by modern digital fabrication technology, we see potential applications in material science, bio- and mechanical engineering, art, design, and architecture.
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