Search for: All records

Abstract Foams are versatile by nature and ubiquitous in a wide range of applications, including padding, insulation, and acoustic dampening. Previous work established that foams 3D printed via Viscous Thread Printing (VTP) can in principle combine the flexibility of 3D printing with the mechanical properties of conventional foams. However, the generality of prior work is limited due to the lack of predictable process‐property relationships. In this work, a self‐driving lab is utilized that combines automated experimentation with machine learning to identify a processing subspace in which dimensionally consistent materials are produced using VTP with spatially programmable mechanical properties. In carrying out this process, an underlying self‐stabilizing characteristic of VTP layer thickness is discovered as an important feature for its extension to new materials and systems. Several complex exemplars are constructed to illustrate the newly enabled capabilities of foams produced via VTP, including 1D gradient rectangular slabs, 2D localized stiffness zones on an insole orthotic and living hinges, and programmed 3D deformation via a cable‐driven humanoid hand. Predictive mapping models are developed and validated for both thermoplastic polyurethane (TPU) and polylactic acid (PLA) filaments, suggesting the ability to train a model for any material suitable for material extrusion (ME) 3D printing. 

The growing demands for computational power in cloud computing have led to a significant increase in the deployment of high-performance servers. The growing power consumption of servers and the heat they produce is on track to outpace the capacity of conventional air cooling systems, necessitating more efficient cooling solutions such as liquid immersion cooling. The superior heat exchange capabilities of immersion cooling both eliminates the need for bulky heat sinks, fans, and air flow channels while also unlocking the potential go beyond conventional 2D blade servers to three-dimensional designs. In this work, we present a computational framework to explore designs of servers in three-dimensional space, specifically targeting the maximization of server density within immersion cooling tanks. Our tool is designed to handle a variety of physical and electrical server design constraints. We demonstrate our optimized designs can reduce server volume by 25--52% compared to traditional flat server designs. This increased density reduces land usage as well as the amount of liquid used for immersion, with significant reduction in the carbon emissions embodied in datacenter buildings. We further create physical prototypes to simulate dense server designs and perform real-world experiments in an immersion cooling tank demonstrating they operate at safe temperatures. This approach marks a critical step forward in sustainable and efficient datacenter management. 

Foams, essential for applications from car seats to thermal insulation, are limited by traditional manufacturing techniques that struggle to produce graded stiffness, a key feature for enhanced functionality. Here, we introduce a novel slicing algorithm for producing heterogeneous foams through viscous thread printing (VTP). Our slicer generates a single, global toolpath for the entire foam volume while modulating the viscous thread’s self-interactions along this path to program stiffness. The slicer integrates multiple meshes into a unified print space and interpolates the print speed and height based on specified mesh parameters to program the desired stiffness variations. Using both qualitative samples and quantitative compression tests, we demonstrate that our slicer can (1) generate foam stiffnesses spanning an order of magnitude, (2) achieve millimeter precision in stiffness control, and (3) continuously vary stiffness between regions of constant stiffness using arbitrary functional forms. 

Storage, organizing, and decorating are important aspects of home design. Buying commercial items for many of these tasks, this can be costly, and reuse is more sustainable. An alternative is a “home hack,” i.e., a functional assembly constructed from existing household items. However, coming up with such hacks requires combining objects to make a physically valid design, which might be difficult to test if they are large, require nailing or screwing to the wall, or if the designer has mobility limitations. We present a design and visualization system, FabHacks, for cre- ating workable functional assemblies. The system is based on a new solver-aided domain-specific language (S-DSL) called FabHaL. By analyzing existing home hacks shared online, we create a design abstraction for connecting household items using predefined con- nection types. We also provide a UI for designing hack assemblies that fulfill a given specification. FabHacks leverages a physics-based solver that finds the expected physical configuration of an assembly design. Our validation includes a user study with our UI, which shows that users can easily create assemblies and explore a range of designs.