Getting inspiration from programmable metal stamping machines that use several linear actuators in a grid to create stamped sheet metal without one-off tooling, I embarked on a several month long project to design and build a 2.5-D molding machine. Using a similar design of linear actuators in a grid, 3D printed toppers could be attached to the tops of the actuators to create detailed topography without wasted support material. I worked with a partner, who created a program for importing 3D models, generating G-Code, and controlling the machine.
The final prototype was capable of creating a dome using less material and in less time. I used 3D printing, sheetmetal, extrusion, and modular design techniques to make an easily assembleable machine with many repeating components. I also coded the arduino based control system, and made a custom carrier board for the stepper motor drivers.
Animation
The machine with the test dome (in red) model in CAD.
Early physical prototype
This early proof of concept was made with mostly scrap materials and was a proof of concept for the electronics, programming, and design of the later improved model.
