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AI-based design tools are proliferating in professional software to assist engineering and industrial designers in complex manufacturing and design tasks. These tools take on more agentic roles than traditional computer-aided design tools and are often portrayed as “co-creators.” Yet, working effectively with such systems requires different skills than working with complex CAD tools alone. To date, we know little about how engineering designers learn to work with AI-based design tools. In this study, we observed trained designers as they learned to work with two AI-based tools on a realistic design task. We find that designers face many challenges in learning to effectively co-create with current systems, including challenges in understanding and adjusting AI outputs and in communicating their design goals. Based on our findings, we highlight several design opportunities to better support designer-AI co-creation. 

Thermoset elastomers are widely used high‐performance materials due to their thermal stability, chemical resistance, and mechanical properties. However, established casting and molding techniques limit the overall 3D complexity of parts that can be fabricated. Advanced manufacturing methods such as 3D printing have improved design flexibility and reduced development time but have proved challenging using thermally‐cured thermosets due to their viscosity, slow gelation kinetics, and high surface tension. To address this, freeform reversible embedding (FRE) 3D printing extrudes thermosets such as polydimethylsiloxane (PDMS) elastomer within a carbomer support bath, but due to the liquid‐like state of the prepolymer during extrusion has been limited to hollow structures. Here, FRE printing is significantly improved through rheological modification of PDMS with a thixotropic additive (1.0–10.0 wt.%) that imparts a yield stress (30–120 Pa) to help control filament morphology. Further, print process controls consisting of region‐specific slicing, filament retraction, and nonprint travel moves outside of the print to minimize the interaction of the nozzle with previously printed PDMS are implemented. The combined result is the FRE printing of PDMS in complex 3D parts with high fidelity, establishing a 3D printing methodology that can be used broadly with thermally‐cured thermoset elastomers and related polymers.

 

From providing nutrition to facilitating social exchanges, food plays an essential role in our daily lives and cultures. In HCI, we are interested in using food as an interaction medium and a context of personal fabrication. Yet, the design space of available food printing methods is limited to shapes with minimal overhangs and materials that have a paste-like consistency. In this work, we seek to expand this design space by adapting support bath-assisted printing to the food context. The bath scaffolds the embedded materials and preserves shapes during the printing processes, enabling us to create freeform food with fluid-like materials. We provide users guidelines for choosing the appropriate support bath type and processing methods depending on the printing material's properties. A design tool suite and application examples, including confectionery arts, 4D printed food, and edible displays are also offered to demonstrate the enabled interaction design space. 

Thermally cured thermoset polymers such as epoxies are widely used in industry and manufacturing due to their thermal, chemical, and electrical resistance, and mechanical strength and toughness. However, it can be challenging to 3D print thermally cured thermosets without rheological modification because they tend to flow and not hold their shape when extruded due to cure times of minutes to hours. 3D printing inside a support bath addresses this by allowing the liquid polymer to be held in place until the thermoset is fully cured and expands the structures that can be printed as extrusion is not limited to layer‐by‐layer. Here, the use of Freeform Reversible Embedding (FRE) to 3D print off‐the‐shelf thermoset epoxy into lattice structures using nonplanar extrusion is reported. To do this, the authors investigate how extrusion direction in 3D space impacts epoxy filament morphology and fusion at filament intersections. Furthermore, the advantages of this approach are shown by using nonplanar printing to produce lattice geometries that show ≈ four times greater specific modulus compared with lattice structures printed using other materials and printing techniques.

 

Morphing structures are often engineered with stresses introduced into a flat sheet by leveraging structural anisotropy or compositional heterogeneity. Here, we identify a simple and universal diffusion-based mechanism to enable a transient morphing effect in structures with parametric surface grooves, which can be realized with a single material and fabricated using low-cost manufacturing methods (e.g., stamping, molding, and casting). We demonstrate from quantitative experiments and multiphysics simulations that parametric surface grooving can induce temporary asynchronous swelling or deswelling and can transform flat objects into designed, three-dimensional shapes. By tuning the grooving pattern, we can achieve both zero (e.g., helices) and nonzero (e.g., saddles) Gaussian curvature geometries. This mechanism allows us to demonstrate approaches that could improve the efficiency of certain food manufacturing processes and facilitate the sustainable packaging of food, for instance, by creating morphing pasta that can be flat-packed to reduce the air space in the packaging.