We propose a technical method and system to enable an unmodified FDM 3D printer to fasten fabric in a manner analogous to traditional sewing. Rows of printed “needles” pierce layers of fabric with “thread” printed to fasten them together. This recreates traditional kinds of stitches while also enabling new ones. A technical evaluation shows the strength is as good or better than traditionally sewn seams. Using this sewing inspired joinery method, a software system translates traditional sewing patterns into a multi-step workflow. Steps are ordered and grouped to balance automation with traditional sequencing for human fabric handling. Intermittent requests by the system require the user to place fabric pieces aided by printed registration marks. A study suggests people with little experience can use the system and complete necessary fabric handling steps. Finally, enhanced types of seams are presented, such as decorative stitches, rivets, fringes, and print-in-place fasteners like buttons and zippers.

We contribute a technical solution to reduce print time and material with unmodified fused deposition modelling printers. The approach uses ad hoc objects inserted by a user during printing as a replacement for printed support of overhanging structures. Examples of objects include household items like books, toy bricks, and custom mechanisms like a screw jack. A software-only system is integrated into existing slicing software to analyze generated support print paths, search a library of objects to find suitable replacements, optimize combinations of replacement objects, and make necessary adjustments to impacted printing layers and paths. During printing, the user is prompted to insert objects with the help of lightweight printed holders to guide placement and prevent movement. Instructions printed on the build-plate help identify and position objects. A technical evaluation measures performance and benefits with different sets of ad hoc objects and different levels of user involvement.

Fabrication devices often appear as “large, clunky cubes”, and the more capable a machine is, the larger it usually is as well. Minus 1D Fabrication investigates decoupling the output dimensions of fabrication machines from the form factor of the machines themselves. We propose designs for pen-shaped laser cutters and book-sized 3D printers, including designs that can increase the build volume without increasing the size of the machine. The resulting form factors assist the integration of fabrication into daily life.

We present a software system for fused deposition modelling 3D printing that replaces infill material with scrap to reduce material and energy consumption. Example scrap objects include unused 3D prints from prototyping and calibration, household waste like coffee cups, and off-cuts from other fabrication projects. To achieve this, our system integrates into an existing CAD workflow and manages a database of common items, previous prints, and manually entered objects. While modelling in a standard CAD application, the system suggests objects to insert, ranked by how much infill material they could replace. This computation extends an existing nesting algorithm to determine which objects fit, optimize their alignment, and adjust the enclosing mesh geometry. While printing, the system uses custom tool-paths and animated instructions to enable anyone nearby to manually insert the scrap material.

We present an interactive editing system for laser cutting called kyub. Kyub allows users to create models efficiently in 3D, which it then unfolds into the 2D plates laser cutters expect. Unlike earlier systems, such as FlatFitFab, kyub affords construction based on closed box structures, which allows users to turn very thin material, such as 4mm plywood, into objects capable of withstanding large forces, such as chairs users can actually sit on. To afford such sturdy construction, every kyub project begins with a simple finger-joint "boxel"-a structure we found to be capable of withstanding over 500kg of load. Users then extend their model by attaching additional boxels. Boxels merge automatically, resulting in larger, yet equally strong structures. While the concept of stacking boxels allows kyub to offer the strong affordance and ease of use of a voxel-based editor, boxels are not confined to a grid and readily combine with kuyb's various geometry deformation tools. In our technical evaluation, objects built with kyub withstood hundreds of kilograms of loads. In our user study, non-engineers rated the learnability of kyub 6.1/7.

In this paper, we explore how to embody mechanical computation into 3D printed objects, i.e., without electronic sensors, actuators, or controllers typically used for this purpose. A key benefit of our approach is that the resulting objects can be 3D printed in one piece and thus do not require assembly. We are building on 3D printed cell structures, also known as metamaterials. We introduce a new type of cell that propagates a digital mechanical signal using an embedded bistable spring. When triggered, the embedded spring discharges and the resulting impulse triggers one or more neighboring cells, resulting in signal propagation. We extend this basic mechanism to implement simple logic functions. We demonstrate interactive objects based on this concept, such as a combination lock. We present a custom editor that allows users to model 3D objects, route signals, simulate signal flow, and synthesize cell patterns.

We present TrussFab, an integrated end-to-end system that allows users to fabricate large scale structures that are sturdy enough to carry human weight. TrussFab achieves the large scale by complementing 3D print with plastic bottles. It does not use these bottles as "bricks" though, but as beams that form structurally sound node-link structures, also known as trusses, allowing it to handle the forces resulting from scale and load. TrussFab embodies the required engineering knowledge, allowing non-engineers to design such structures and to validate their design using integrated structural analysis. We have used TrussFab to design and fabricate tables and chairs, a 2.5 m long bridge strong enough to carry a human, a functional boat that seats two, and a 5 m diameter dome.

Recently, researchers started to engineer not only the outer shape of objects, but also their internal microstructure. Such objects, typically based on 3D cell grids, are also known as metamaterials. Metamaterials have been used, for example, to create materials with soft and hard regions.

Laser cutters are useful for rapid prototyping because they are fast. However, they only produce planar 2D geometry. One approach to creating non-planar objects is to cut the object in horizontal slices and to stack and glue them. This approach, however, requires manual effort for the assembly and time for the glue to set, defeating the purpose of using a fast fabrication tool. We propose eliminating the assembly step with our system LaserStacker. The key idea is to use the laser cutter to not only cut but also to weld. Users place not one acrylic sheet, but a stack of acrylic sheets into their cutter. In a single process, LaserStacker cuts each individual layer to shape (through all layers above it), welds layers by melting material at their interface, and heals undesired cuts in higher layers. When users take out the object from the laser cutter, it is already assembled. To allow users to model stacked objects efficiently, we built an extension to a commercial 3D editor (SketchUp) that provides tools for defining which parts should be connected and which remain loose. When users hit the export button, LaserStacker converts the 3D model into cutting, welding, and healing instructions for the laser cutter. We show how LaserStacker does not only allow making static objects, such as architectural models, but also objects with moving parts and simple mechanisms, such as scissors, a simple pinball machine, and a mechanical toy with gears.