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.

Laser cutting has a long tradition of building load-bearing 3D objects based on box joints and T-joints, as these joints are naturally robust against compression and shearing. Achieving robustness against tension, however, is challenging. One presumed solution is to make all joints extremely tight, to the point where they can only be assembled using a mallet. However, our survey found that making joints tight can cause models to break during assembly. In this paper, we identify the 10 underlying issues and present techniques for overcoming them: by extending parts with what we call scaffolding or by adjusting the models’ assembly order, so as to bypass states that are subject to these issues. Based on our user study and analysis of laser-cut models, scaffolding speeds up assembly for an average of 14% of the assembly operations per model, which in turn gives an average of 1.3x speed-up per model, and 70% of the models would benefit from the adjusted assembly order, that in the absence of such, would require higher assembly effort.

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 FoolProofJoint, a software tool that simplifies the assembly of laser-cut 3D models and reduces the risk of erroneous assembly. FoolProofJoint achieves this by modifying finger joint patterns. Wherever possible, FoolProofJoint makes similar looking pieces fully interchangeable, thereby speeding up the user's visual search for a matching piece. When that is not possible, FoolProofJoint gives finger joints a unique pattern of individual finger placements so as to fit only with the correct piece, thereby preventing erroneous assembly. In our benchmark set of 217 laser-cut 3D models downloaded from kyub.com, FoolProofJoint made groups of similar looking pieces fully interchangeable for 65% of all groups of similar pieces; FoolProofJoint fully prevented assembly mistakes for 97% of all models.

We present HingeCore, a novel type of laser-cut 3D structure made from sandwich materials, such as foamcore. The key design element behind HingeCore is what we call a finger hinge, which we produce by laser-cutting foamcore “half-way”. The primary benefit of finger hinges is that they allow for very fast assembly, as they allow models to be assembled by folding and because folded hinges stay put at the intended angle, based on the friction between fingers alone, which eliminates the need for glue or tabs. Finger hinges are also highly robust, with some 5mm foamcore models withstanding 62kg. We present HingeCoreMaker, a stand-alone software tool that automatically converts 3D models to HingeCore layouts, as well as an integration into a 3D modeling tool for laser cutting (Kyub [7]). We have used HingeCoreMaker to fabricate design objects, including speakers, lamps, and a life-size bust, as well as structural objects, such as functional furniture. In our user study, participants assembled HingeCore layouts 2.9x faster than layouts generated using the state-of-the-art for plate-based assembly (Roadkill [1]).

Recently, there has been an excessive congestion occurring in the driving environment because of the presence of modern gadgets inside the car and increased traffic on the roads, which has resulted in a higher demand for the visual and cognitive senses. This prompted the need to reduce the demand to make driving experience safer and more comfortable. Consequently, a novel steering wheel design for in-car controls is presented in this paper. The new design introduces dual ubiquitous touch panels embedded in the steering wheel for interaction with in-car controls and haptic feedback as positive reinforcement upon successful execution of an in-car control. There are eight different functionalities that can be controlled using the embedded touch panels. The proposed system is compared with a standard car regarding its efficacy using the NASA task load index (NASA-TLX) evaluation technique. The results showed that the proposed system significantly reduced the drivers’ visual, cognitive, and manual workload.

We present fastForce, a software tool that detects structural flaws in laser cut 3D models and fixes them by introducing additional plates into the model, thereby making models up to 52x stronger. By focusing on a specific type of structural issue, i.e., poorly connected sub-structures in closed box structures, fastForce achieves real-time performance (106x faster than finite element analysis, in the specific case of the wheelbarrow from Figure 1). This allows fastForce to fix structural issues continuously in the background, while users stay focused on editing their models and without ever becoming aware of any structural issues.

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.

We present Roadkill, a software tool that converts 3D models to 2D cutting plans for laser cutting—such that the resulting layouts allow for fast assembly. Roadkill achieves this by putting all relevant information into the cutting plan: (1) Thumbnails indicate which area of the model a set of parts belongs to. (2) Parts with exposed finger joints are easy to access, thereby suggesting to start assembly here. (3) Openings in the sheet act as jigs, affording assembly within the sheet. (4) Users continue assembly by inserting what has already been assembled into parts that are immediately adjacent or are pointed to by arrows. Roadkill maximizes the number of joints rendered in immediate adjacency by breaking down models into “subassemblies.” Within a subassembly, Roadkill holds the parts together using break-away tabs. (5) Users complete subassemblies according to their labels 1, 2, 3…, following 1 -> 1 links to insert subassemblies into other subassemblies, until all parts come together. In our user study, Roadkill allowed participants to assemble layouts 2.4 times faster than layouts generated by a traditional pair-wise labeling of plates.

Getting laser-cut mechanisms, such as those in micro-scopes, robots, vehicles, etc., to work, requires all their components to be dimensioned precisely. This precision, however, tends to be lost when fabricating on a differ-ent laser cutter, as it is likely to remove more or less mate-rial (aka 'kerf'). We address this with what we call kerf-canceling mechanisms. Kerf-canceling mechanisms replace laser-cut bearings, sliders, gear pairs, etc. Unlike their tradi-tional counterparts, however, they keep working when manufactured on a different laser cutter and/or with different kerf. Kerf-canceling mechanisms achieve this by adding an additional wedge element per mechanism. We have created a software tool KerfCanceler that locates traditional mecha-nisms in cutting plans and replaces them with their kerf-canceling counterparts. We evaluated our tool by converting 17 models found online to kerf-invariant models; we evaluated kerf-canceling bearings by testing with kerf values ranging from 0mm and 0.5mm and find that they perform reliably independent of this kerf.