Ezgi Hakan V. Martinez. Anadolu University, Eskisehir, Turkey

Transcription

1 Journal of Literature and Art Studies, ISSN February 2012, Vol. 2, No. 2, D DAVID PUBLISHING New Technologies of Ceramic Product Design 3D Softwares (Computer Aided Programs) Integrated Into Design Practices in the Field of Ceramic Art Education Ezgi Hakan V. Martinez Anadolu University, Eskisehir, Turkey In the 21st century the use of computers in the field of product design has become inevitable. 3D softwares are being widely used in the three dimensional functional ceramics designs as well as spreading in computer generated creative studio ceramics. While the pioneer industries are concentrating on the professional CAD (computer aided design)/cam (computer aided manufacturing) manufacturing processes as a new experience of ceramic design and production, pioneer education institutions introduce these new technology systems to their students to become more conscious of the developments in their field of ceramic art education. By this approach students also become aware of new aspects of visual expressions while dealing with the problem of a range of product line from table ware to sanitary wares during the courses. In this study, computer, seen as a new tool for expressing the creativity by interdisciplinary applications, is discussed and explained with examples by means of improving designing skills in a different direction getting away from making centered process while approaching shortened period of virtual modeling. Keywords: ceramics, design, computer, CAD (computer aided design), 3D Introduction Computers have diffused into the design medium all over the world since more than 50 years. Commonly used by designers and design companies these hardware systems are inevitably the most important need of 21st century. Together with, 3D softwares have become the main tools for three dimensional design and production procedures spreading in the computer generated functional ceramics and creative studio ceramics world by means of CAD (computer aided design)/cam (computer aided manufacturing) applications. Description of CAD/CAM/CNC (Computerized Numerical Control) CAD which is a term that refers to Computer Aided Design is widely used as a concept in the 21st century in the field of product design. It can be defined as use of computer systems to assist in creation, modification, analysis, and optimization of a design. CAM is a term that means Computer Aided Manufacturing which integrates manufacturing and design in All images in the paper are drawings of various students in the course of Computer Aided 3D Industrial Ceramics Design at Anadolu University, Faculty of Fine Arts, Ceramics Deparment. Ezgi Hakan V. Martinez, assistant professor, Ceramic Department, Faculty of Fine Arts, Anadolu University.

2 330 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN the production process. It can be defined as use of computer systems to plan, manage, and control operation of manufacturing plant through computer interface with production resources. CNC systems are the new manufacturing production processes in the industry. They are being used widely in the industry of mass production in the last 20 years all over the world as well as in Turkey to reach the contemporary production quality assurance in the industry varying from small scale manufactories to full equipped factories. This system controls operation of machines to produce prototypes or moulds for industry. The main function of these are creating commands that would read the points on the computer generated model in the language of the control units of the CNC machines to make production. Brief History of CAD/CAM System In the 1950s, the computer graphics project called Automatically Programmed Tools has been evolved and has developed followingly as the inital of CAM systems. In 1960s, the Skecth pad project of a researcher from MIT (Massachusetts Institute of Technology) has been a start point of such theoretical basis for computer graphics softwares. These interactive computer graphics in the early 1960s can be indicated as the origin of CAD technologies. The development of CAD programs gained an extreme speed in the 1970s in USA, Japan, and Europe, as the capacity of computers started to rise and emerged in the design offices. As the languages of computer programs were developed integration between data bases and these languages has been improved. But still it was very expensive and not as widely used and not as easy to install as today. In the 1980s, the softwares were developing and new modules were being added to the Cad field gradually for converting 2D images to 3D forms with volume, edges and for modeling solid-surface as it was limited before. The pioneer companies were Pro-engineer, Solid works, and Unigraphics. In the 1990s, the connection between Parametric Solid Modeling and 3D CAM began to be established. With increasing speed, the three-dimensional CAD applications were found at almost any level and for any kind of purpose in the industry. However, CAD/CAM industry was unstable, because some of the companies which bankrupt or merged, for instance programs like Ideas were merged to Unigraphics. After their merge Ideas disappeared in the market. The word, upgrade was no longer available; the only option for customers was Unigraphics software, to keep the data of previous softwares. Current State and Use of CAD/CAM Technology In various companies of industrial production some of the softwares in last 10 years have been Autocad, Ideas-UniGraphics, Coral Draw, Solidworks, 3D Max, DeskArte s, Catia, Rhinoceros, and Alias. Today 3D Modeling is a part of toy, automobile, footwear, container, ceramics, tableware, jewelry, packaging, furniture designs, aircraft engine modeling, and architectural applications, etc. While today s computer and software systems are technically answering problems of the design process to a great extent, it is still in progress of development with the new demands of users and the industry, changing so quickly as fast as computer industry changes, forming the technology base of computer integrated factories and systems of the future. Between late 1990s and beginning of 21st century, popularity of personal computers, windows programs, and low cost hardware appeared. Technique was improved in time, so it brought Hybrid Modeling and application to

3 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN 331 variety of materials. Computer Operation System became unified and standardized. PC (personal computers) became affordable and powerful enough to be used almost in any kind of three dimensional designing. Benefits of Using CAD/CAM & CNC Systems Using CAD/CAM & CNC systems in the production process brings together various benefits and advantages in manufacturing: (1) to shorten process of design and production and decrease the number of the mistakes in production (This solves the problem of time and financial consuming); (2) data enrolment and control by making an archive of data base easily (This provides easiness to keep and share data files to transfer one design to number of designers (while modeling); (3) easy management of technology to decrease the number of prototype and analyzes (This decreases the need for engineering staff); and (4) easy to make a standard and control (This provides healthy communication of project group for agreement). Working Process of CAD/CAM Systems in the Factories The process of product design concerned with ceramics field in the industry requires care of steps to make a well planned production. This process is made up of two work stages: design and production. In the design stage the steps can be defined as follows: (1) Problem Identification: to identify the need; (2) Preliminary Ideas: brainstorming; (3) Refinement Process: measurements, interactions of surfaces and planes, dimensions; (4) Analysis of Process: due to criteria of cost, function, marketability; (5) Decision Process: selecting the design which has desirable characters like qualified, quickly manufacturable, available for the customer; and (6) Implementation: making drawings for developing process plans. In the production process including the design stage the steps can be formed up with following mediums: (1) definition of the need or request; (2) forming the product concept; (3) design process by CAD; (4) drafting; (5) computer process planning; (6) CAM program; (7) NC (Numeric Control) data; and (8) NC carving of the mould. Necessity of CAD/CAM in Ceramic Design It is known that in the ceramic industry the product developments and manufacturing are complex and time consuming processes involving much manual labor. After the designer s visualizations, many skillful people and time is necessary. Moreover, artistic and engineer perspectives must be combined to solve the design and production problems together. Currently many ceramic factories and design studios all over the world are starting to use CAD systems in their designing processes and CAM systems in model and mold making to shorten the period of wasted time because in the CAD/CAM systems corrections and changes are also possible so that design team and production managers can criticize and agree to continue in every stage of the production in a shorter time. Using CAD/CAM brings together high creativity for designing in the process after the 3D modeling enables to prepare data for manufacturing and links all the production steps and assures the qualified production in the ceramic production as well as all other manufacturing plants. In Turkey Eczacıbaşı Ceramic Factory and Serel Factory for sanitary ware in Turkey are also using this CAD/CAM and CNC Rapid Prototyping systems. Implementation of 3D Softwares in Ceramics Education Today converting 2D applications into 3D modeling became easier and techniques have improved for

4 332 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN modeling easier which was more complex before. Accordingly at the end of the 20th century after the availability of desktop computers at the university laboratories, useful software s of the design sector have been installed and it has become one of the most important tools of learning in the design courses accompanied by the designers and 3D modelers from the industry as guest lecturers. Since 1999, Department of Ceramics at the author s faculty at Anadolu University offers ceramic students have been introduced computer aided three dimensional functional ceramic design courses to improve their 3D computer skills. The students started such an education model for the first time with ideas Integrated Design Engineering and Analyses Software. Subsequently as the program was merged under roof of Unigraphics NX program, our department upgraded to NX5 in 2007 which was improved with easier menus which bring together: (1) getting reference from older drawings; (2) quick drawing commands like copy, trim, move after drawing curves; (3) easy to examine the results and make parametric changes; (4) easy to change design, texture, and pattern; (5) visualization opportunities by using various textures, surfaces, and environmental images to increase the quality of presentations; and (6) control over the elements of a project. Requirements and Aims of Computer Aided 3D Ceramics Design Courses Unlike shaping clay or plaster, computer aided modeling on the 2D screen 3D modeling is additive process which allows the students to experience possibilities to gain forms by simple solid volumes. However, while taking this course, the students are required to have basic technical drawing knowledge and the skills of model and mould making by means of industrial production to deal with unique ceramic product design problems like the shell thickness, model angles for coming of the mould, and foot height in the aim to perfectly finalize the procedure of model, mould, and firing. Therefore, taking these details into consideration while teaching computer skills, this course is being offered at the 4th year after the students master fundamentals of their profession. The aims of this course can be listed as: (1) to present the possibilities of softwares, (2) to encourage the students to be creative via computer while developing new ceramic forms (mostly functional), and (3) to expand Cad possibilities in ceramic design linked with art. Content of the Course: Tools for Designing and Implementation Steps In the content of this course directly designing or drawing via digital programs cannot be recommended because computer is accepted only as a tool to make a design directly. Hand drawing by pencil as the initial tools of design can be defined as the easiest way to reflect and visualize the design ideas that appear in the mind of a designer after making a research on the concept of the project, such as teapot, tableware, sanitary wares like sink basin, etc.. In this course, computer is seen just as an equipment to express and see what the design would look like at the end of production by means of form, size texture, and volume to make inference from all data and parameters to define the product with dimensions. While paper-based designs can only offer suggestive impressions, making Cad drawings would result fully defined with fine details of every point of view. So it is an advantage for the student to experience CAD practices to with useful experiments in the creative process. By this way development of fundamental design skills are also believed to be reinforced (see Figure 1).

5 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN 333 Figure 1. Primarily sketches on the work plane. Technical drawing is the basis of such programs. Technical drawing means 2D drawings which consist of visual and numerical statements and is necessary for production process of a design. So while converting hand sketches to 2D drawings, it is important to imagine the three views of the object and combine the three seen on the 3D. The sections (top view-left-right-bottom-front-back) of products form the final product with the meshed surfaces or solid parts (see Figures 2-3). Figure 2. Front view section on the XY work plane. Figure 3. Revolved model from front view section around the axis. So this course is obviously based on the mathematical systems and skills as well. Artists and designers do not know and fortunately are not even expected to know much utility of mathematics behind the computer programs. Despite the theoretical and technological innovations, most of the available CAD systems are supported by engineers or industrial designers rather than artists and designers. Luckily, the very recent development in CAD system s user interfaces seem to have improved that situation so that students of fine arts

6 334 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN can also deal with and manage to use CAD softwares at least at the level of beginning. On the other hand, it is an enjoyable discovery to be free to zoom in and out to observe the details and scale the form that you create on the screen especially for fine arts students who deal with aesthetics. Experiencing 3D modeling it brings immediate satisfaction to see the result and gives motivation. So students show higher efforts to improve their skills and finalize the project supported with other 3D softwares as well. Unigraphics is one of the CAD programs that allow creating 3D forms by drawing sections based on X, Y, and Z axis on the coordinate system and then easily simulate three dimensions. To start modeling using NX5 software, it is necessary to start with technical drawing of a design which can be drawn with computer aid via 2D softwares using basic elements of point line, arc and polygons, additionally copying scaling, moving, and trimming; options can be used to make necessary changes. While using commands in the curve toolbar to create top, front, or side sections of the form, students get used to the interface and have a medium understanding of program structure and the organization of menus: curve, feature, and feature operation toolbars. 3D softwares are available to make solid modeling by creating basic geometric volumes just as cylinder, sphere, cone, pyramid, cube, and prism sections revolved around one axis or extruded through one direction determined (see Figure 4). Figure 4. Modeled cube and sphere. By sweeping or combining curve sections new creative forms can be produced. Then these forms can be used as base of the design which is the variations of new forms. For gaining creative forms uniting, subtracting, or deforming parts of basic volumes, new forms might be gained for example by using subtract to make creative removal or carve out from the form or to unite and separate forms by dividing, splitting body, repetitive copy or overlapping (see Figures 5-7). Figure 5. United cube and sphere-creative combination.

7 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN 335 Figure 6. Subtracted cube from sphere-creative removal. Figure 7. Subtracted sphere from cube-carve out. After constructing lines in 2D views, solid forms can be gained by using these sections in various ways even in solid forms or surface structures. The easiest way to create a 3D seen is to make sectional wire frame geometry of a form (see Figure 8). Figure 8. Drawing lines or arcs or splines to create front view of a plate. It would be enough to draw exterior edges with or shell by tools of line or arcs or splines, which would form the solid body by using revolving and extruding feature tools. After feature operations for giving shell to create thickness and edge blend to soften the edges of the whole form would be enough to maintain realistic view of the final form (see Figures 9-10). Figure 9. Revolving front view of a plate to create solid body with thickness.

8 336 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN Figure 10. Modeled plate with edge blend. By sweeping or sewing meshes through curves, sheets can also be used to create surfaces by coming together to form a feature (see Figure 11). Figure 11. The use of surface command (Through curve mesh) to create a body of surfaces. Cad drafting might be used to form technical drawings derived from the 3D model (see Figure 12). Figure 12. Technical drawing of a sink basin derived from the 3D of the model by NX5. The opportunities of CAD are demonstrated during the classes in the process of advancing modeling skills of students. Accordingly, at the end of the first semester, the students become generally familiar with the program which would provide them to master the program commands in the following semester for concentrating on the design, not the tools. On the other hand, NX5 software provides render function in its license that allows us to create image as real object (see Figure 13). Figure 13. 3D modeled Sink basin by NX5.

9 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN 337 Working environment can also be changed to imagine a final product completely and clearly. By means of visualization there are selectively displaying contents and opportunity to load new displaying textures, playing with the material information (see Figures 14-16). Figure 14. 3D Render of a sink basin by 3D Max Studio. Figure 15. 3D Render of a tea set by 3D Max Studio. Figure 16. 3D visualization of a tea cup shaded by NX5 visualization module. Accordance with this application, the designer easily integrates with the finished piece as a realistic form to imagine the existence of the form in the space (see Figures 17-18). Figure 17. 3D Render of a dinner set by NX5 visualization module.

10 338 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN Figure 18. 3D Render of a dinner set by NX5 visualization module. Such programs can include other modules or can be supported by other programs. For instance, in Kangnam University in South Korea, separate softwares are being used such as Powershape, Artcam, Copycad, and Powermill for professional modeling in collaboration with the industry, and each software has a separate function for modeling, surface designs, and visualization used one after the other to complement the operation. Conclusions By means of this unique approach design course, constructed on the demand of these processes in ceramics design, besides working on free hand drawings and sketches and being aware of every step of production process, the students experience and get involved with such an education model with 3D softwares, contributing them to strengthen and intensify their design knowledge while practicing theoretical buildup and to be familiar with CAD/CAM concepts which are the inevitable stages of the new century s basic industrial production system. Because primarily functionality and calculation of total costs and potential clients are considered by product development departments at the very first stage of design, these systems must be conducted by specialists who have enough experience of materials and whole process of designing, good knowledge of production process like model-mould forming and finishing procedures. After the CAD/CAM systems entered the ceramic factories, engineers replaced alumni who have industrial and artistic ceramic design education. However, artistic and engineer perspectives must combine to solve the design and production problems together, so graduates of ceramic art departments should take their place in the sector just as it was before. The graduates of this implementation sample would be very adequate in knowledge and experiences of computer aided designs and also will be preferred to be employed as they can easily be integrated due to critics of these departments that work on production stage. Getting involved with computer aided design, this would provide our students to become more conscious of new aspects of visual expressions by exploring different equipments for expressing the creativity and to take place in the professional CAD/CAM process in industry after graduation as candidate experts of the field. In this way, they would find different points of view as computer aided design provides useful and experimental experiences in the creative process. Contributing to the new education experiences, we believe this is a unique approach in ceramic design education system that encourages the university-industry collaboration in the future.

11 NEW TECHNOLOGIES OF CERAMIC PRODUCT DESIGN 339 References Groover, M. P., & Zimmers, E. M. (1984). CAD/CAM computer aided design and manufacturing. London: Prentice/Hall International, Inc.. Jacobs, S. P. (1991). The cad design studio, 3D modelling as a fundamental design skill. New York: Mc Graw-Hill, Inc., R. R. Donnelley & Sons Company. Marshall, J. (2002). Computers and creativity. Ceramic Review, 194, Raino, R. (1993). Interaction in ceramics-art, design and research (Conference notes, University of Art and Design Helsinki, Department of Ceramics and Glass: CAD/CAM IN CERAMIC DESIGN 1993, ISBN , ISSN , UIAH, Helsinki, Finland). Singh, N. (1996). Systems approach to computer-integrated design and manufacturing. USA: John Willey & Sons, Inc.. Türkel, E. (2008). Modelling ceramic products by using computer aided design softwares and an implemantation of urinal design (Pulished doctorate thesis, Arts, Dokuz Eylul University, Izmir, Turkey). Yong, L. W. (2007). Ceramics design process aided CAD/CAM & CNC machine (Paper presented at the SERES VI. Uluslararası Katılımlı Seramik, Cam, Emaye, Sır ve Boya Semineri, 2007, October, Eskişehir, Turkey). ZHANG, Z. G., SUN, Y. S., XIAO, X. T., & MA, Z. G. (2007). sanitary ceramic products CAD system based on application development of unigraphics. Journal of Computer-Aided Design & Computer Graphics, 19(6),