Generative Design for climbing holds
As an Undergraduate Research intern at University of Illinois' Engineering Systems and Design Lab I set out to rapidly produce rock climbing holds designed through generative algorithms. To do this I had to answer a few questions:
My approach to answering these questions was to first get a proof of concept for questions 1 and/or 2 and if they were possible, to begin work on question 3.
- Is it possible to 3D print molds for artificial rock climbing holds?
- Is it possible to program a Dremmel to mill and carve out molds for artificial rock climbing holds?
- Is it possible to use generative algorithms to create interesting shapes and textures for such holds in CAD software?
My approach to answering these questions was to first get a proof of concept for questions 1 and/or 2 and if they were possible, to begin work on question 3.
Question 1
Is it possible to 3D print molds for artificial rock climbing holds?
I needed to find out if complex geometries and textures could be 3D printed using a Makerbot . I scanned some climbing holds using Autodesk's 123D Catch, and applied textures to the models using Autodesk's Meshmixer. I 3D printed the textured models on a Makerbot and was surprised to find that the Makerbot was able to print the highly complex geometry files.
After the prints were successful, the next step was to create the silicone molds by mixing silicone with a catalyst and pouring the mix around the 3D printed geometries. Once the mix solidified, the 3D printed cores were removed. The last step to making the final climbing holds was mixing the Polyurethane with its catalyst,
and pouring that mixture into the cavity that the 3D printed geometry left behind.
and pouring that mixture into the cavity that the 3D printed geometry left behind.
Now with the final Polyurethane holds in hand, I headed to the campus climbing gym to test with users. Conveniently, I worked at the climbing gym at the time and had the authority to bolt my holds to the wall. I asked patron climbers, and fellow staff members what they thought about the texture of the holds. Unfortunately The texture was not gritty enough respective to a normal climbing hold. The texture I had applied to the geometries was the maximum resolution a Makerbot was capable of printing, but it was not good enough to be used in a climbing gymnasium.
Answer 1:
Not in this case. At their best performance, Makerbot 3D printers cannot print at a high enough resolution to provide the rock-like gritty texture that rock climbers expect from their climbing holds.
Question 2:
Is it possible to program a Dremmel to mill and carve out molds for artificial rock climbing holds?
I needed to find out if a CNC programmed Dremmel execute the highly complex maneuvers necessary to carve rock climbing holds. I followed a similar approach in Question 1 and scanned a professionally carved mold of climbing hold using 123D Catch.
With this Scanned geometric data, I was able to generate the G-Code that the CNC programmed Dremmel (Shapeoko) would accept. I attempted the CNC Dremmel carving program on a block of floral foam.
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I found that the G-Coded Dremmel, or Shapeoko, was actually quite capable of carving fairly complex 3D shapes from floral foam. However since the Shapeoko is limited to 3 degrees of freedom, this process is not capable of carving out "overhangs" which can be important to rock climbers and are known as "jugs" in the rock climbing community.
Answer 2:
Yes, the programmed Dremmel is capable of carving out molds for climbing holds that have the same texture quality that climbers are used to. However, this process has limited geometry and cannot create "overhangs", or "jugs".
Question 3:
Is it possible to use generative algorithms to create interesting shapes and textures for such holds in CAD software?
Now that I knew the computer models could translate to acceptable climbing holds, I needed to find if algorithms could be used to generate the geometry and textures of those models. I used a plug-in of the computer moddeling software, Rhino, called Grasshopper and was able to create rudimentary algorithms that were capable of generating 3D geometries that could have textures applied to the and used for rock climbing,
Answer 3:
Yes. Algorithms can be used to create textured 3D geometries. Generative algorithms can create more interesting geometries with new exciting textures.
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