Thursday, January 22, 2009

The Dubai Bridge Project

Making the most of a digital model is key.

Once you've got a 3D CAD file it makes sense to use it in as many ways as possible.
Rendering, animation, 3D Print. In this case the model was used for 4 total 3D printed models. 1 model was replicated 3 times while being combined with a laser cut base and the 4th was built at a much larger scale combined with excellent craftsmanship in the art of model making.

What started out as some messy STL files turned out to be a big winner for the client.
Models designed in Rhino

The files were partially fixed in Rhino using mesh tools and in Magics on our end. (see previous post for more details about Magics)

After the fixing we printed the models on the Objet machine. The models were used in conjunction with clear plexi as a base and the models were mounted. We did a series of tests before the full model was produced. Using FDM (Dimension) machine, High Speed Objet and High Quality Objet. The architects were new to the technology so they wanted to see the differences. The samples gave them the clarity they needed and they went with High Quality Objet in white. The model was going to be quite small and all curvature they wanted perfectly smooth so the resolution had to be very high. Oh yeah, the models were painted white.



In terms of size, the base is about 2 feet long. Looks bigger than it is.






Incredibly we were able to print the wire beams that connect to the bridgeway, but they were so thin that they would bend when you hold them. That wasn't going to work. So to work around this problem we helped them design tiny holes in the bridge arch and the roadway so that metal wire could be inserted as a post process. This also went through tests. It was really exciting to see their faces when the whole thing started to come together.




Well they brought the model to the Shiek in Dubai and wallah. He wanted it for himself and of course, he wanted another one. And not just more of the same but he also wanted one much bigger. So that is exactly what they did. We replicated that same model a total of 3 times.



For the larger model we used the same 3D file with some small adjustments. The brigde was cut into sections. This time they used the Dimension machine. Taking advantage of the strength and its light weight were advantagous for such a large model.


















The model was built in sections and then sealed together by heating metal latches till they were very hot and placed them half on one piece and half on another. Each piece between the metal latches is roughly 12 inches long.


When you zoom in you can see better.

















And finally as it gets put together from one of NY city's best model makers.















Notice that he is surrounding the model in a thin sheet of wood. This is for the surface finish. I asked him, "just use the wood and forget the protoype, all you need is the outside!" He responded. "We can't use regular wood because the shape is too complex, traditional methods won't work. Also, the balsa wood we're using isn't strong enough to suspend the bridge roadway. There is no other way to do this than to prototype it".

And the final pictures. They were able to build this model from the same 3D file. It was sliced into separate sections so each could fit inside the bed of the machine.