Harnessing plastic deformation in porous 3D printed ceramic light screens

Abstract

Traditional fabrication methods of architectural ceramics seek to minimize plastic deformation during wet-processing by prioritizing sectional consistency. Adapting sectional thickness is critical for improving material performance to address localized functional requirements. Functionally Graded Additive Manufacturing (FGAM) enables a design-to-production process where sectional profiles can be designed to achieve targeted performance characteristics. This research utilizes FGAM with Liquid Deposition Modelling (LDM) to prioritize sectional performance over form generation. Functionally graded 3D printed ceramic screens are produced for decorative lighting applications. Custom tool path generation is implemented to create modelling techniques that capitalize on the viscoelastic properties of clay. The prototypes obstruct, reflect, and transmit light across their component sections to grade brightness and illumination. This paper outlines the methods involved in altering plastic deformation during the wet-processing of porous clay structures and the corresponding light-scattering behaviour of their ceramic counterparts. The light screens are organized by the resolution of porosity within each series of prototypes. In the 'Small' typology, deformation is utilized at the scale of a single print layer to form a dense multi-layered sectional condition that disperses light evenly. In the 'Medium' typology, deformation is compounded over multiple layers to form directional light apertures. In the 'Large' typology, extrusion variation is introduced to exaggerate deformation and generate multi-directional light scattering.