We present a fabrication system called AirForce that allows users to create large-scale, load-bearing animated structures from a single inflatable tube. AirForce builds on the personal fabrication of animated truss structures, based on which it replaces not only the static elements with tube, but also introduces tube-based actuators that integrate with that same tube. This ‘single-tube’ design affords efficient single-person assembly, excellent power-to-weight ratio, easy transport and setup, and 100% material reuse. We show three variants of actuators: buckling actuators for pushing, muscle actuators for pulling, and telescoping actuators for large forces. Our blender plugin enables users to place actuators in structures and export instructions for efficient fabrication. We demonstrate a 6DOF motion platform that lifts humans and an 8m high animatronic T-rex that animates with 3DOF, enabled by custom hardware components. In our technical evaluation, the three actuators delivered 480N, 1420N, and 2330N peak forces, respectively.

We present Kerfmeter, a hardware + software device that automatically determines how much material the laser cutter burns off, also known as kerf. Its knowledge about kerf allows Kerfmeter to make the joints of laser cut 3D models fit together with just the right tension, i.e., loose enough to allow for comfortable assembly, yet tight enough to hold parts together without glue—all this without user interaction. Kerfmeter attaches to the head of a laser cutter and works as follows: when users send a model to the laser cutter, Kerfmeter intercepts the job, injects a brief calibration routine that determines kerf, dilates the cutting plan according to this kerf, and then proceeds to fabricate the cutting plan. During the calibration routine, Kerfmeter cuts a 2cm Archimedean spiral and uses a motor to rotate it in place until it jams against the surrounding material; the angle at which the spiral jams allows Kerfmeter to infer kerf. The calibration process takes about 20s, which is >10x faster than traditional, manual kerf calibration, while also eliminating the need for expertise. In our technical evaluation, Kerfmeter produced functioning press fit joints reliably at a precision comparable to traditional manual kerf strips. Kerfmeter makes it easy to sample repeatedly; we demonstrate how this allows boosting precision past any traditional kerf strip.

We present AirTied, a device that fabricates truss structures in a fully automatic fashion. AirTied achieves this by unrolling a 20cm-wide inflatable plastic tube and tying nodes into it. AirTied creates nodes by holding onto a segment of tube, stacking additional tube segments on top of it, tying them up, and releasing the result. The resulting structures are material-efficient and light as well as sturdy, as we demonstrate by creating a 6m-tower. Unlike the prior art, AirTied requires no scaffolding and no building blocks, bringing automated truss construction into the reach of personal fabrication.

We present Assembler3 a software tool that allows users to perform 3D parametric manipulations on 2D laser cutting plans. Assembler3 achieves this by semi-automatically converting 2D laser cutting plans to 3D, where users modify their models using available 3D tools (kyub), before converting them back to 2D. In our user study, this workflow allowed users to modify models 10x faster than using the traditional approach of editing 2D cutting plans directly. Assembler3 converts models to 3D in 5 steps: (1) plate detection, (2) joint detection, (3) material thickness detection, (4) joint matching based on hashed joint "signatures", and (5) interactive reconstruction. In our technical evaluation, Assembler3 was able to reconstruct 100 of 105 models. Once 3D-reconstructed, we expect users to store and share their models in 3D, which can simplify collaboration and thereby empower the laser cutting community to create models of higher complexity.

Trusscillator is an end-to-end system that allows non-engineers to create human-scale human-powered devices that perform oscillatory movements, such as playground equipment, workout devices, and interactive kinetic installations. While recent research has been focusing on generating mechanisms that produce specific movement-path, without considering the required energy for the motion (kinematic approach), Trusscillator supports users in designing mechanisms that recycle energy in the system in the form of oscillating mechanisms (dynamic approach), specifically with the help of coil-springs. The presented system features a novel set of tools tailored for designing the dynamic experience of the motion. These tools allow designers to focus on user experience-specific aspects, such as motion range, tempo, and effort while abstracting away the underlying technicalities of eigenfrequencies, spring constants, and energy. Since the forces involved in the resulting devices can be high, Trusscillator helps users to fabricate from steel by picking out appropriate steal springs, generating part lists, and producing stencils and welding jigs that help weld with precision. To validate our system, we designed, built, and tested a series of unique playground equipment featuring 2-4 degrees of movement.

Recent research showed how to import laser cut 3D models encoded in the form of 2D cutting plans into a 3D editor (assembler3 [28]), which allows users to perform parametric manipulations on such models. In contrast to assembler3 , which requires users to perform this process manually, we present autoAssembler, which performs this process automatically. AutoAssembler uses a beam search algorithm to search possible ways of assembling plates. It uses joints on these plates to combine them into assembly candidates. It thereby preferably pursues candidates (1) that have no intersecting plates, (2) that fit into a small bounding box, (3) that use plates whose joints fit together well, (4) that do not add many unpaired joints, (5) that make use of constraints posed by other plates, and (6) that conform to symmetry axes of the plates. This works for models that have at least one edge joint (finger or t-joint). In our technical evaluation, we imported 66 models using autoAssembler. AutoAssembler assembled 79% of those models fully automatically; another 18% of models required on average 2.7 clicks of post-processing, for an overall success rate of 97%.