Qian, AF; Shi, Z; Tan, YX; Zhuang, Y; Wu, R; Anderson, JS; King, N; Qian, AF; Shi, Z; Tan, YX; Zhuang, Y; Wu, R; Anderson, JS; King, N; Stuart-Smith, R; - view fewer (2024) Variable Pneumatic Thermoforming Robotic Thermal Welding for Volumetric Thermoplastic Building Envelope Panels. In: ACADIA 2024: Designing Change - Proceedings Volume 1 for the 2024 Association for Computer Aided Design in Architecture Conference. (pp. pp. 397-408).

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Abstract

Thermoplastic sheets are widely used in manufacturing due to their formability and recyclability, and typically manufactured into volumetric forms by thermoforming or pressure-forming processes. Such industrial techniques require a mold that renders shape variation challenging within a single production run. This research explores the integration of robotic thermal welding techniques to guide a variable pneumatic thermoforming process, testing this method to unlock the potential for custom, repeatable, and controlled bespoke fabrication using thermoplastic sheets. The process utilizes a custom end-effector and a 6-axis robotic manipulator to selectively laminate two PETG sheets using thermal welding. First, a perimeter with a specific boundary profile is welded that contains the inflation forming. Within that boundary, points, lines, and curves are distributed to create unique thermal welding patterns to generate varied volumetric formal outcomes. Post-lamination, the sheets are heated to their glass transition temperature, and inflated with pressurized air. This technique results in semi-rigid volumetric components with an inner cavity and a consistent boundary condition. Following a series of prototypes that proved the efficacy of the manufacturing process, a simulation model was developed and utilized to inform the design of a multi-part proof of concept. The comprehensive workflow consisting of design, simulation, iteration, and robotic fabrication is tested through the fabrication of a large-scale prototype. The outcomes of this process are discussed throughout the paper, thus presenting a feasible alternative to current thermoplastic thermoforming practices and future opportunities for the digital fabrication of thermoplastic building envelopes.

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