Robotic Bandsawing

Robotic Bandsawing

With edge curvature approximating a chaise longue.

Cherry Flitch

With edge curvature approximating a chaise longue.

Algorithm for nesting designed freeform surface into the bounds of a 3D scanned Flitch.

Nesting Process

Algorithm for nesting designed freeform surface into the bounds of a 3D scanned Flitch.

Upright bandsaw reconfigured into robot end effector.

End Effector

Upright bandsaw reconfigured into robot end effector.

Nested bands and alignment holes.

Detail

Nested bands and alignment holes.

Wood grain and bark edges provide process narrative and clarify zero waste concept.

Detail

Wood grain and bark edges provide process narrative and clarify zero waste concept.

Produced with practically zero waste, by strategically designing the surface into the available geometry of the live-edged cherry flitch.

Prototypical chaise longue surface

Produced with practically zero waste, by strategically designing the surface into the available geometry of the live-edged cherry flitch.

Substantial Efficiency Gains: CNC milling vs. Flitch Nesting for a sample surface.

Process Comparison

Substantial Efficiency Gains: CNC milling vs. Flitch Nesting for a sample surface.

The algorithm allows for a variety of surface geometries to nest within these constraints.

Material Morphospace

The algorithm allows for a variety of surface geometries to nest within these constraints.

Optimized for movement in areas of higher twist and curvature

Cut Speed

Optimized for movement in areas of higher twist and curvature

Angled and placed algorithmically, and drilled by the robot before sawing

Dowel Holes

Angled and placed algorithmically, and drilled by the robot before sawing

Unfolding a large continuous surface from a small amount of wood, by nesting surfaces within neighboring flitches taken from the same trunk section.

Scalability

Unfolding a large continuous surface from a small amount of wood, by nesting surfaces within neighboring flitches taken from the same trunk section.

using 'Mussel'

Code Generation

using 'Mussel'

nested back into flitch volume after drilling and sawing.

Sliced Bands

nested back into flitch volume after drilling and sawing.

Assembly

Assembly

executed with a stationary bandsaw and dimensional lumber held by the robot.

Early Prototypes

executed with a stationary bandsaw and dimensional lumber held by the robot.

cut from dimensional lumber.

Nested Bands

cut from dimensional lumber.

assembled from nested bands

Chair Surface

assembled from nested bands

Project Title:  Bandsawn Bands
Dates:  2012 (Initial Research) 2014 (First Publication)
Project Lead:  Ryan Luke Johns, Nicholas Foley
Ongoing

This project demonstrates an innovative technique for designing and fabricating freeform surfaces within the constraints of live-edged wood flitches. By 3D scanning a naturally curved tree section and designing into the available material, we are able to unfold a compact amount of wood into a smooth, continuous topological surface (i.e. furniture or architecture).

The process utilizes a robotically operated bandsaw to cut a series of curved strips which, when rotated and laminated, can approximate doubly-curved and digitally defined geometry. The thin kerf of the bandsaw blade allows for a tight nesting of finished surfaces, which, through a close relationship between available material and designed geometry, affords practically zero waste when compared to CNC contour milling. This coordination of non-standard material geometries, 3D scanning, parametric algorithms, designer input and robotic control serves to bolster the role of feature-based material intuition in design and sustainable manufacturing.

For more information, see: Johns, R and Foley, N 2014 ‘Bandsawn Bands: Feature-Based Design and Fabrication of Nested Freeform Surfaces in Wood.’ In: McGee, W and Ponce de Leon, M (eds) Robotic Fabrication in Architecture, Art and Design. Springer. pp 17-32.  [Text available here]