Thermoformable digital fabrication

Abstract

Digital fabrication has replaced most traditional model-making in physical prototyping with great convenience and accuracy. However, unlike model-making, users can only make or modify their design through virtual modeling. In this thesis, we bring thermoforming into the 3D printing context to engage users' hands-on deformation after printing. Thus far, thermoforming is not practically applicable owing to two critical issues: invisible malleable states and hardly heating solid geometries. To address these issues, we present three approaches: a temperature-sensitive 3D filament and two metamaterial structures. Each approach or combination of approaches is compatible with off-the-shelf fused deposition modeling 3D printers. The facilitated thermoforming could enrich the post-print process's design space and make the fabrication process flexible. We investigate the effects of thermoforming on digital fabrication in terms of process and physical prototyping. Finally, we believe that our approaches and a series of insights can help in integrating digital fabrication with crafting.