ROBOTIC INCREMENTAL SHEET Ammar Kalo University of Michigan

METAL FORMING Michael Jake Newsum University of Michigan

1 Forming Variations: Geometry investigations looking

into the viability of forming dual curvature, variable
curvature, multi-directional curvature, and/or
multi-axis valleys (Kalo and Newsum 2013).
Building on previous and current work, this research utilizes the Single Point Incremental
Forming (SPIF) process to produce mass customized, double-curved (both positive
and negative Gaussian curvature), three-dimensional forms from sheet metal. These
forms are produced at a scale that suggests their use as cladding elements in a building
envelope. This, combined with the relative speed and efficiency of production and the
variability of resultant geometries, allows for speculation on the production of high per-
formance façade systems directly from digital models.

71
2 SPIF: A diagram showing the setup of a robotic single point incremental forming
(SPIF) work cell (Kalo and Newsum 2013).
4 Materials: Several materials including steel, aluminum, brass, and copper were
tested for formability (Kalo and Newsum 2013).
This project demonstrates a number of proof of concept studies for
single point incremental forming as a viable technique to produce
highly variable, double curved panels in sheet materials, without the
requirement of expensive forming dies (Figure 1). The project also
provides a model for the development of a materially informed pro-
duction process, integrating design and fabrication into a stream-
lined production methodology.
Single point incremental forming is a process whereby a sheet of
metal is incrementally deformed at local points to achieve an overall
geometry (Figure 2). Typically, the stock is formed using a hemispher-
ical tool that can be attached to a robotic arm or a CNC machine.
The tool moves along a pre-programmed toolpath, as it gradually
steps down into the stock, until forming is complete (Bambach et al.
2009) (Figure 3). Several materials were tested to find the limitations
of the forming process and viability. The sampling of sheet metals
RESEARCH PROJECTS
3 Toolpath: A parametric toolpathing script was developed to guide the robotic arm
to form the desired geometry (Kalo and Newsum 2013).
5 Kalo, Ammar and Michael Jake Newsum (2013) Forming Slopes. Ann Arbor,
Michigan: Realized
included cold rolled steel, aluminum, copper and brass (Figure 4).
Cold rolled steel was used in most of the forming tests because
of its high ductility and strength, which allowed for forming deeper
parts (Figure 5). Once trimmed from the rest of the stock, the formed
geometry would often deform into a new relaxed shape. This re-
lease of internal forces is called springback. The deeper a panel is
formed, the more it would become rigid and resist this deformation
(Kreimeier et al. 2011). Several design strategies, most prominently
the use of performative textures, were utilized to stabilize the com-
ponents pre-trimming (Kalo and Newsum 2014).
Since this investigation seeks to build on previous research on
incremental sheet forming, it addresses questions which are es-
sential to its applicability at an architectural scale, notably the ability
to aggregate multiple panels into a performative system. Various
strategies were explored for connecting formed panels into a larger
ACADIA 2014 DESIGN AGENCY 72
6 Kalo, Ammar and Michael Jake Newsum (2013) Porous Aggregation. Ann Arbor, Michigan: Realized
aggregation. One technique overlapped the valleys and peaks
of doubly curved surfaces and then tack welded the surfaces
together to create a self-structured thickened porous skin condi-
tion (Kalo et al. 2014) (Figure 6).
Similar to bead rolling, adding ribs serves to locally corrugate the
sheet metal, where the geometry is the shallowest, to prevent it
from deforming. The ribs not only function as a performative part
of the process but also have a unique aesthetic quality. In addition,
the ribs could drive a global panel connection strategy. These ribs
were then used as identification points at the edges of panels to
align the aggregation (Figure 7). Geometries were also developed
that shared the same edge perimeter geometry. This allowed for
varying shapes to be formed within this boundary that could be
connected to one another as a continuous aggregation.
73 KALO, NEWSUM
REFERENCES
Kalo, Ammar, Michael Jake Newsum. 2014. “An Investigation of
Robotic Incremental Sheet Metal Forming as a Method for Prototyping
Parametric Architectural Skins.” In Robotic Fabrication in Architecture,
Art and Design 2014, edited by Wes McGee and Monica Ponce de
Leon, 33-49. Switzerland: Springer International Publishing.
Kalo, Ammar, Michael Jake Newsum, and Wes McGee. 2014
“Performing: exploring incremental sheet metal forming methods for
generating low-cost, highly customized components.” In Fabricate:
Negotiating Design and Making, edited by Fabio Gramazio, Matthias
Kohler and Silke Langenberg, 166-173. Zurich: gta Verlag.
Kreimeier, Dieter, Bolko Buff, Christian Magnus, Volker Smukala, and
Junhong Zhu. 2011. “Robot-Based Incremental Sheet Metal Forming
– Increasing the Geometrical Accuracy of Complex Parts.” Key
Engineering Materials 473: 853-860.
Markus Bambach, Babak Taleb Araghi, and Gerhard Hirt. 2009.
“Strategies to Improve the Geometric Accuracy in Asymmetric Single
Point Incremental Forming” Production Engineering 3(2): 145–56.
ROBOTIC INCREMENTAL SHEET METAL FORMING
7 Kalo, Ammar and Michael Jake Newsum (2013) Performative Ribs. Ann Arbor, Michigan: Realized

AMMAR KALO is currently the Director of CAAD Labs in

the Department of Architecture, Art, and Design at the American
University of Sharjah. He recently received a Master of Science in
IMAGE CREDITS Architecture with concentrations in Material Systems and Digital
Figure 1. Kalo, Ammar and Michael Jake Newsum (2013) Forming Technologies at the Taubman College of Architecture and Urban
Variations. Ann Arbor, Michigan: Realized Planning, University of Michigan. In 2014 he received the Kuka Young
Potential Award at the Rob|Arch 2014 conference. Prior to graduate
Figure 2. Kalo, Ammar and Michael Jake Newsum (2013) SPIF. Ann
school, Ammar has gained experience working on international
Arbor, Michigan: Realized
projects of various scales and typologies.
Figure 3. Kalo, Ammar and Michael Jake Newsum (2013) Toolpath.
Ann Arbor, Michigan: Realized
Figure 4. Kalo, Ammar and Michael Jake Newsum (2013) Materials.
MICHAEL JAKE NEWSUM is the Robotics Lab
Coordinator at the Southern California Institute of Architecture
Ann Arbor, Michigan: Realized
where he works with students and faculty on research projects that
Figure 5. Kalo, Ammar and Michael Jake Newsum (2013) Forming investigate the role of robotics in architecture and design. His work
Slopes. Ann Arbor, Michigan: Realized currently focuses on developing robotic design platforms that rethink
the interactions between man and machine. He holds a Master of
Figure 6. Kalo, Ammar and Michael Jake Newsum (2013) Porous
Science in Architecture with a concentration in Digital Technologies
Aggregation. Ann Arbor, Michigan: Realized
from the Taubman College of Architecture and Urban Planning,
Figure 7. Kalo, Ammar and Michael Jake Newsum (2013) Performative University of Michigan. He is also the recipient of the Kuka Young
Ribs. Ann Arbor, Michigan: Realized Potential Award at Rob|Arch 2014.

RESEARCH PROJECTS ACADIA 2014 DESIGN AGENCY 74