Article written by Ysabelle Gamoso
For a long time, traditional model-making methods such as sculpting, carving and casting have been our process of forming objects. We carve statues out of a large piece of stone, we make pots by applying pressure to clay, we create shapes by pouring liquid medium into molds and clone them by repeatedly doing so. In all of these scenarios, there has always been a material to begin with before being reduced, pressed or casted into its desired shape. However, just in the last 30 years, a complete opposite to these traditional methods was developed. This process is called additive manufacturing.
Additive manufacturing is the process of constantly layering a material until it builds up a height and becomes a three-dimensional object. Previously, it could only be done through a giant, expensive machine that only factories could afford. It wasn’t until 2009 that a consumer-friendly desktop-size product was developed. This product is called a 3D printer. For many, the invention of 3D printers is the renaissance of additive manufacturing.
3D printers have become known for their many benefits. Some would say owning a 3D printer is like owning a factory. The possibility of making anything with accuracy with minimal time, labor and resources became easy. This couldn’t be any more obvious during the Covid-19 pandemic where hospitals around the world struggled with lack of PPEs. Many 3D printer owners or “makers” joined forces to produce PPEs and address this shortage. What made this global factory possible is the availability of printer-ready 3D models shared online by the maker community. At thingiverse, you’ll find an entire library of 3D models for literally anything! This made the printer even more appealing even to users who are not well versed on 3D software. Also thanks to this, GW was able to help during the pandemic using our in-house 3D printer.
3D printing has also proven to be a very efficient model-making and design tool here in GW. Its ability to produce physical prototypes of complex volumes in a short amount of time is a huge strength over traditional methods. It has also helped our clients visualize our design intent and is a great support to our 2D drawings and 3D renderings. Oftentimes we find that our clients are more engaged with 3D printed models than sophisticated technical drawings and 3D views on screen. When a model is around, suddenly they can pick it up, look all around it, and really connect with it up close.
Using 3D printer at an urban scale: WPX project, corporate HQ for an energy company in Oklahoma
It also makes for a smooth design-thinking process. Once we print one prototype, we look at it and think about how we can make it better. We go back to our 3D models to produce another iteration, and then print the next prototype. This process carries on until the final volume is achieved. By the time all prototypes are created, we have multiple forms to compare and contrast. 3D printing also allows us to see our design in a different medium. In doing so, we can assess other aspects of the form that we normally wouldn’t discover from looking at our screens alone.
Using 3D Printer at a building scale: Reception desk study for 1700 Market Street project in Philadelphia
3D printers are also environmentally friendly. Not only does it avoid scraps because of its accuracy but the spools itself (the term used for 3D printer “ink”) is made of recyclable plastic. This type of plastic, PLA or polyactic acid, is one of the most used bioplastics in the world. It can be recycled in designated facilities and melted again to make a new spool. Now there are also desktop 3D model recyclers available so any maker can recycle their prototypes right away!
Current GW projects: Study model for a reception desk (first two); Study model for a financial HQ in New York City (last two).
3D printing also has huge benefits beyond the architecture office. It’s been used to make new prototype buildings, not just for earth but even for Mars. It’s been used to make prosthetics that can be easily scaled and re-printed as the body part grows. It can print bones and is being studied to print organs like kidneys. It has also been used to print food, musical instruments, and even coral reefs. Just last year, the Museum of Modern Art launched Neri Oxman’s exhibit called “Material Ecology” where the first ever 3D printed glass was presented. Ceramics can now be printed, too. Both Architect Magazine and Designboom have featured projects that use 3D printed ceramics. The possibilities are endless!
Even if many of these innovations are still in need of longer test and research, 3D printing has indeed expanded the way we make things. As Dr. Tim Minshall calls it in his TED Talk, 3D printing is the “4th industrial revolution,” and we are very excited to see what is yet to come!