Aalto University Digital Design Laboratory, }ADD{

Nanoshell: Cocoon

ADD in collaboration with Olli Ikkala is developing a technique in 3D printing nanocellulose. Embracing the relationship with departments that have the expertise in developing future materials allows the research to go beyond pure simulation to thinking of future application processes.

Parallel to ADD’s research the ADD Opportunity seminar was held at UCLA with a focus on design as a method for exploring new applications and business potentials of additive manufacturing technologies, and nanoscopically structured fibrous cellulose.


Nanoshell: Emoto Glove

Fully Customizable 3D Printed Motorcycle Glove
Students: Ryan Hong and Andrew Raffel

The market for motorcycle gloves is limited, so someone looking for a personalized high performance Moto GP glove finds their choices limited to different colors.

Flexibility, performance and protection have been maximized with attention to detail and design. Where the rider is the most exposed, the glove’s design creates the greatest distance between skin and asphalt to minimize risk in case of crash.

Individual joints allow for the maximum range of motion required for steering flexibility. The aim has also been to let the motorcyclist feel more at one with the bike without losing grip or protection. The glove was created at Solid Concepts Inc. using a process called Selective Laser Sintering (SLS), which allows for a high level of control as well as detail within the desired design. In this case, the customer would have their hand scanned, or create a digital model in which a unique glove can be printed. To ensure personalization, the customer would be involved throughout the design process. A high level of customization once reserved for the most elite is now easily accessible for any passionate rider.


Nanoshell: Fashion Shoe

Students: Marie Trabold, Roshanak Mostaghim

All feet are unique, but the selection of heels is more limited, often constrained by beauty. Since heels can’t cater to all heels, the result is some amount of discomfort.

This proposal introduces a shoe that delivers a tailored fit by scanning the foot, while simultaneously creating an interesting contemporary organic look. Through the use of multi-material 3D printing, the heel delivers a level of comfort not traditionally attainable with conventional methods.


Nanoshell: Cavity Skateboards

Students: Jac Currie, Mo Harmon, and Tas Oszkay

Customers can customize their own 3D printed skateboard to order through a digital interface with variables including size and shape. Variety characterizes the skateboarding market, where new styles of skating are constantly causing diversions. A recent example of this is the boom in small plastic cruiser decks, most famously manufactured by Penny Australia. Cavity Skateboards recognizes their success but pushes the medium using 3D printing technology to produce a more refined product.

The intricate mineral skeletons of Radiolaria have served as performative and geometric inspiration throughout the development of this project. Their thin strained-like skeletons are structurally strong and durable yet also extremely lightweight. Emulating key aspects of this geometry serves the purpose for structural and esthetic value of the skateboard, but it also truly takes advantage of the additive manufacturing process. Traditional manufacturing would not be able to achieve the intricacy and complexity of the board's design. 3D printing to reach the high performance required, while maintaining the product's light weight. The result is a skateboard unlike anything ever seen before.

The shape of the board was designed with convex curvature and as the weight of the skater is applied, the board will naturally deflect downward compressing into a flat surface. This allows more of the material to remain in compression.

The aim was to introduce students to the cutting-edge of digital design and manufacturing, and then to go beyond that edge to create new design innovations to drive technical and scientific research.


Nanoshell: Splint

Additive Manufacturing for Limb Trauma
Students: Nicholas Solakian, Derek Buell, and Peter Nguyen

International aid organizations ship billions of dollars of aid and relief supplies to people in need around the world. The research looks at the possible demand for 3D printed, on-demand products in such disaster and conflict affected areas.

Direct Relief International (DRI), based in Santa Barbara, CA, works in high-need areas to improve health care and deliver medical supplies in 70 countries around the world. Director of International Programs at DRI, Brett Williams, advised with the possible need and use of 3D printed medical supplies in their relief work.

3D printing technology would allow much higher quality products to be printed on-demand, replacing packaging and shipping supplies around the world and saving resources. Clear advantages would be achieved with today's limitations in the manufacturing of the medical splint.


Nanoshell: Unity

The World’s Most Seamless Soccer Boot
Students: Brian Barnes, Jacob Bloom, Adam Rude

Soccer footwear and protection equipment have historically been separate: cleats and shin guards each performing a unique and independent function. As a result of the discontinuities between cleats and shin guards cause, large bumps occur on the top and sides of the feet and the shins, which can lead to erratic strikes of the soccer ball.

Multi-material 3D printing and the application of fibrous structural organizations allow for cleats and shin guards to be combined into a single seamless boot.

Variable composite assembly.


PROJECT COLLABORATORS:
UCLA School of Architecture and Urban Design,
UCLA Technology Seminar Sotamaa:
Brian Barnes
Jacob Bloom
Derek Buell
James Currie
Timothy Harmon
Ryan L Hong
Hongkai Li
Steven Matti
Roshanak Mostaghim
Peter Nguyen
Tas Febres-Cordero
Andrew Raffel
Adam Rude
Nicholas Solakian
Marie Trabold
Zhuoran Xu

Department of Applied Physics
Aalto School of Science
Olli Ikkala, Academic Professor
Henrikki Mertaniemi, Researcher

ADD TEAM:
Kivi Sotamaa, Director
Ashish Mohite, Design Research
Emmy Maruta, Design Research