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TU Delft
                                Acoustics by
                                Additive Manufacturing
                                Foteini Setaki
                                foteini.setaki@gmail.com
                                2012
Technische Universiteit Delft




                                         Challenge the future
Framework




DESIGN
PROCESS
ACOUSTIC            ACOUSTIC   MATERIAL
PANEL           PERFORMANCE




  COMPUTATION



                                      FABRICATION
                                          ADDITIVE
                                          MANUFACTURING


                                          2 Acoustics by Addtive Manufacturing
AM in
                                                           Acoustics




Loughborough University   ETH Zurich                    CITA Copenhagen

                                       3 Acoustics by Addtive Manufacturing
Acoustics




Auditorium   Office        School Class




                      4 Acoustics by Addtive Manufacturing
D = 2.50cm
                                Additive
                              Manufacturing




             5 Acoustics by Addtive Manufacturing
Common
                                                                              Process


01    CAD     02      STL     03         FILE TRANSFER   04    MACHINE SETUP

                              FILE
                              TRANSFER




                                            3D                 SET
     CAD           SAVE AS:                 PRINTER
                   .STL                                        UP



05    BUILD   06    REMOVE    07         POST-PROCESS    08     APPLICATION




                                                         6 Acoustics by Addtive Manufacturing
PDI-Absorber


                                LOCAL GEOMETRY

                                       Concept: Passive
                                       Destructive Interference
                                SCENARIO 2:
                                HELMHOLTZ ABSORBER Passive destructive interference




            f = c/ 2(l2 - l1)

[c] speed of sound in air
   [l1] length of the short
                   air path
 [l2] length of the longer
                   air path




                                                                                      7 Acoustics by Addtive Manufacturing
                                SCENARIO 4:
Principles



                                                                   f = (2n-1) c / 2 (L2 - L1)

                                                                                            [f]
                                                                                  frequency
                                                                                           [c]
                      Point of Interference:                                        speed of
                       180o out of phase                                        sound in air
                                                                                          [n]
                                                                             random integer
                                                                                         [L1]
                                                                               length of the
                                                                              short air path
                                                                                         [L2]
                                                                               length of the
                                                                               long air path

        Short Path:                       Long Path:
                L1                        L2 = L1 + ΔL




Incident Sound Wave
                                                         8 Acoustics by Addtive Manufacturing
Phase 1




03

     06   04


               05   02




                                  01
                                                     07




                         9 Acoustics by Addtive Manufacturing
Measurements

Impedance Tube
[sample diameter: 3cm]




                         Fabrication:
                         ZCORP Z310




                           10 Acoustics by Addtive Manufacturing
Samples
                 Diameter
         n 0.1

Ltot = 10.28cm
D = 1.00 cm




                                            Geometry                       Length

         n 0.2                      n 0.4                      n 0.6

Ltot = 10.28cm              Ltot = 36.7cm              Ltot =19.55cm
D = 0.75 cm                 D = 0.5 cm                  D = 0.5 cm




         n 0.3                      n 0.5                      n 0.7

Ltot = 10.28cm              Ltot =19.55cm              Ltot = 36.7cm
 D = 0.5 cm                  D = 0.5 cm                D = 0.5 cm




                                                             11 Acoustics by Addtive Manufacturing
Phase 2




12 Acoustics by Addtive Manufacturing
Measurements
Impedance Tube
[sample diameter: 3/ 10cm]




                             Fabrication:
                             EOSINT P 730




                               13 Acoustics by Addtive Manufacturing
High
                    Frequencies




14 Acoustics by Addtive Manufacturing
SMALL SAMPLES
                                                                                               Small
    D = 3.00cm                                                                                Samples
    H =3.00/ 9.00/ 10.00cm

     n1.1                    n1.2             n1.3

     Ltot = 10.28cm          Ltot = 10.28cm   Ltot = 10.28cm
     D = 1.00cm              D = 0.75 cm      D = 0.5 cm




     n2.1                    n2.2             n2.4             n2.5                          n2.3

     Ltot = 34.30cm          Ltot = 34.30cm   Ltot = 17.15cm   Ltot = 17.15cm                SOLID
     D = 1.00cm              D = 0.75cm       D = 1.00cm       D = 0.75cm




                                                                        15 Acoustics by Addtive Manufacturing
Low-Mid
                    Frequencies




16 Acoustics by Addtive Manufacturing
Big
                                                                                      Samples
                        D =10.00cm
                        H =10.00cm




     BIG SAMPLES: DIAMETER
                  MEASUREMENT’S ACCURACY




n3.1.A 3.1.B                  n3.2.A 3.2.B     n3.3.A 3.3.B

Ltot = 52.13cm                Ltot = 52.13cm   Ltot = 52.13cm
D = 1.00cm                    D = 2.00cm       D = 3.00cm




                                                                17 Acoustics by Addtive Manufacturing
Big
                                                                                                                                  Samples
                                          D =10.00cm                             D =10.00cm
                                          H =10.00cm                             H =10.00cm
                                                                                    6.00cm
                                                                                     ---



       BIG SAMPLES: LENGTH                                    BIG SAMPLES: THICKNESS / [NO]CAP/ GEOMETRY




n3.4                         n3.5                      n3.6                             n3.7                           n3.8

Ltot = 34.30cm               Ltot = 108.30cm           Ltot = 29.21cm                   Ltot = 29.21cm                 Ltot = 29.21cm
D = 2.00cm                   D = 2.00cm                D = 2.50cm                       D = 2.50cm                     D = 2.50cm




                                                                                                           18 Acoustics by Addtive Manufacturing
Big
                                                                                                   Samples




       BIG SAMPLES: COMBINATIONS/ DIAMETER SCALING




n4.1                           n4.2                       n4.3             n4.4

2*L1 + L2                      L1 + L2 + L3               5*D              5*L
L1 = 34.3cm                    L1 = 34.3cm/ L2 = 68.6cm   Ltot = 19.28cm   Ltot = 52.13cm
L2 = 68.6cm                    L3 = 51.5cm                D = 2.00cm       D = 2.00 - 1.00cm
D = 1.50cm                     D = 1.50cm




                                                                             19 Acoustics by Addtive Manufacturing
Summary




      Relation between
      Geometry & Performance


01   Coherence with Theory

02   Interference Point

03   Length

04   Diameter

05   Material Thickness



                             20 Acoustics by Addtive Manufacturing
Summary




     Relation between
     Geometry & Performance

06   Accuracy

07   Grading Cross-Section

08   Multiple Channels

09   Exposed Geometry

10   Position of the holes

11   Distance between
     adjacent air-paths
                             21 Acoustics by Addtive Manufacturing
Design
                                                     Guidelines



      Design Guidelines


01   Length
      1
          /4 Ltot < ΔL < Ltot

02   Diameter

      0.75 cm < D < 2.5 cm

03   Predicting Peak Frequencies
      1
          /4 Ltot < ΔL < Ltot




                                22 Acoustics by Addtive Manufacturing
Future




      Suggestions for the Future


01   Material Resolution

02   Distance between air-paths

03   Geometry of air-path

04   Average values




                             23 Acoustics by Addtive Manufacturing
Phase 3




24 Acoustics by Addtive Manufacturing
Applications




CERTAIN TYPES               SMALL RE
                INTERIORS           GION        COMPLEX GEOM-
OF BROADBAND                                    ETRY
SIGNAL/
LOW/ MEDIUM
FREQUENCIES




                                           25 Acoustics by Addtive Manufacturing
Design
                      Proposal




26 Acoustics by Addtive Manufacturing
Design
                             Proposal



Core




              Units




       27 Acoustics by Addtive Manufacturing
Design
(x,y)                                                                                                              Steps
Architectural Constraints
Acoustic Demands

D                                   W                                        R = λ/8
Architectural Constraints           Targeted Frequency                       Targeted Frequency
Acoustic Demands                                               W                                         R
Fabrication Constraints




                            (x,y)




                  D




                  (x,y)


         01_Define Points                    02_Define “absorbing space” -            03_Define distance between
                                                Iso-Curves                               air-paths
         01_Define Points                    02_Absorbing Space                      03_Distance between
                                                                                     Air-paths




                                                                                      28 Acoustics by Addtive Manufacturing
Design
                                                                                                                  Steps




r                                        d
Distance   01_Define Points
                                         Diameter: 02_Define “absorbing space” -         03_Define distance between
1-4cm                                    0.75cm < r < 2.5 cm
                                                       Iso-Curves                           air-paths
                          r


                                                                                   d




           04_Define position of sound                 05_Draw Air-paths                 06_Final outcome
              entrance of air-paths
           04_Entrances                                 05_Air-Paths                     06_Final Outcome




                                                                                       29 Acoustics by Addtive Manufacturing
Distribution




                                                               400 Hz



                                                               500 Hz

                                                               750 Hz
                                                               1000 Hz
                                                               1500 Hz




500 Hz   1000 Hz




         400 Hz




                            1500 Hz




                   750 Hz




                                      30 Acoustics by Addtive Manufacturing
Unit




End Parts                     End Parts




This part of   This part of
the tube is    the tube is
constant       constant


Middle          Middle
Point           Point




                                          31 Acoustics by Addtive Manufacturing
Fabrication
         1           Concepts




         2




         3




         4




32 Acoustics by Addtive Manufacturing
Perspective
                       View




33 Acoustics by Addtive Manufacturing
Perspective
                       View




34 Acoustics by Addtive Manufacturing
Visits




35 Acoustics by Addtive Manufacturing
Collaborations




36 Acoustics by Addtive Manufacturing

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Foteini Setaki - Acoustics by Additive Manufacturing

  • 1. TU Delft Acoustics by Additive Manufacturing Foteini Setaki foteini.setaki@gmail.com 2012 Technische Universiteit Delft Challenge the future
  • 2. Framework DESIGN PROCESS ACOUSTIC ACOUSTIC MATERIAL PANEL PERFORMANCE COMPUTATION FABRICATION ADDITIVE MANUFACTURING 2 Acoustics by Addtive Manufacturing
  • 3. AM in Acoustics Loughborough University ETH Zurich CITA Copenhagen 3 Acoustics by Addtive Manufacturing
  • 4. Acoustics Auditorium Office School Class 4 Acoustics by Addtive Manufacturing
  • 5. D = 2.50cm Additive Manufacturing 5 Acoustics by Addtive Manufacturing
  • 6. Common Process 01 CAD 02 STL 03 FILE TRANSFER 04 MACHINE SETUP FILE TRANSFER 3D SET CAD SAVE AS: PRINTER .STL UP 05 BUILD 06 REMOVE 07 POST-PROCESS 08 APPLICATION 6 Acoustics by Addtive Manufacturing
  • 7. PDI-Absorber LOCAL GEOMETRY Concept: Passive Destructive Interference SCENARIO 2: HELMHOLTZ ABSORBER Passive destructive interference f = c/ 2(l2 - l1) [c] speed of sound in air [l1] length of the short air path [l2] length of the longer air path 7 Acoustics by Addtive Manufacturing SCENARIO 4:
  • 8. Principles f = (2n-1) c / 2 (L2 - L1) [f] frequency [c] Point of Interference: speed of 180o out of phase sound in air [n] random integer [L1] length of the short air path [L2] length of the long air path Short Path: Long Path: L1 L2 = L1 + ΔL Incident Sound Wave 8 Acoustics by Addtive Manufacturing
  • 9. Phase 1 03 06 04 05 02 01 07 9 Acoustics by Addtive Manufacturing
  • 10. Measurements Impedance Tube [sample diameter: 3cm] Fabrication: ZCORP Z310 10 Acoustics by Addtive Manufacturing
  • 11. Samples Diameter n 0.1 Ltot = 10.28cm D = 1.00 cm Geometry Length n 0.2 n 0.4 n 0.6 Ltot = 10.28cm Ltot = 36.7cm Ltot =19.55cm D = 0.75 cm D = 0.5 cm D = 0.5 cm n 0.3 n 0.5 n 0.7 Ltot = 10.28cm Ltot =19.55cm Ltot = 36.7cm D = 0.5 cm D = 0.5 cm D = 0.5 cm 11 Acoustics by Addtive Manufacturing
  • 12. Phase 2 12 Acoustics by Addtive Manufacturing
  • 13. Measurements Impedance Tube [sample diameter: 3/ 10cm] Fabrication: EOSINT P 730 13 Acoustics by Addtive Manufacturing
  • 14. High Frequencies 14 Acoustics by Addtive Manufacturing
  • 15. SMALL SAMPLES Small D = 3.00cm Samples H =3.00/ 9.00/ 10.00cm n1.1 n1.2 n1.3 Ltot = 10.28cm Ltot = 10.28cm Ltot = 10.28cm D = 1.00cm D = 0.75 cm D = 0.5 cm n2.1 n2.2 n2.4 n2.5 n2.3 Ltot = 34.30cm Ltot = 34.30cm Ltot = 17.15cm Ltot = 17.15cm SOLID D = 1.00cm D = 0.75cm D = 1.00cm D = 0.75cm 15 Acoustics by Addtive Manufacturing
  • 16. Low-Mid Frequencies 16 Acoustics by Addtive Manufacturing
  • 17. Big Samples D =10.00cm H =10.00cm BIG SAMPLES: DIAMETER MEASUREMENT’S ACCURACY n3.1.A 3.1.B n3.2.A 3.2.B n3.3.A 3.3.B Ltot = 52.13cm Ltot = 52.13cm Ltot = 52.13cm D = 1.00cm D = 2.00cm D = 3.00cm 17 Acoustics by Addtive Manufacturing
  • 18. Big Samples D =10.00cm D =10.00cm H =10.00cm H =10.00cm 6.00cm --- BIG SAMPLES: LENGTH BIG SAMPLES: THICKNESS / [NO]CAP/ GEOMETRY n3.4 n3.5 n3.6 n3.7 n3.8 Ltot = 34.30cm Ltot = 108.30cm Ltot = 29.21cm Ltot = 29.21cm Ltot = 29.21cm D = 2.00cm D = 2.00cm D = 2.50cm D = 2.50cm D = 2.50cm 18 Acoustics by Addtive Manufacturing
  • 19. Big Samples BIG SAMPLES: COMBINATIONS/ DIAMETER SCALING n4.1 n4.2 n4.3 n4.4 2*L1 + L2 L1 + L2 + L3 5*D 5*L L1 = 34.3cm L1 = 34.3cm/ L2 = 68.6cm Ltot = 19.28cm Ltot = 52.13cm L2 = 68.6cm L3 = 51.5cm D = 2.00cm D = 2.00 - 1.00cm D = 1.50cm D = 1.50cm 19 Acoustics by Addtive Manufacturing
  • 20. Summary Relation between Geometry & Performance 01 Coherence with Theory 02 Interference Point 03 Length 04 Diameter 05 Material Thickness 20 Acoustics by Addtive Manufacturing
  • 21. Summary Relation between Geometry & Performance 06 Accuracy 07 Grading Cross-Section 08 Multiple Channels 09 Exposed Geometry 10 Position of the holes 11 Distance between adjacent air-paths 21 Acoustics by Addtive Manufacturing
  • 22. Design Guidelines Design Guidelines 01 Length 1 /4 Ltot < ΔL < Ltot 02 Diameter 0.75 cm < D < 2.5 cm 03 Predicting Peak Frequencies 1 /4 Ltot < ΔL < Ltot 22 Acoustics by Addtive Manufacturing
  • 23. Future Suggestions for the Future 01 Material Resolution 02 Distance between air-paths 03 Geometry of air-path 04 Average values 23 Acoustics by Addtive Manufacturing
  • 24. Phase 3 24 Acoustics by Addtive Manufacturing
  • 25. Applications CERTAIN TYPES SMALL RE INTERIORS GION COMPLEX GEOM- OF BROADBAND ETRY SIGNAL/ LOW/ MEDIUM FREQUENCIES 25 Acoustics by Addtive Manufacturing
  • 26. Design Proposal 26 Acoustics by Addtive Manufacturing
  • 27. Design Proposal Core Units 27 Acoustics by Addtive Manufacturing
  • 28. Design (x,y) Steps Architectural Constraints Acoustic Demands D W R = λ/8 Architectural Constraints Targeted Frequency Targeted Frequency Acoustic Demands W R Fabrication Constraints (x,y) D (x,y) 01_Define Points 02_Define “absorbing space” - 03_Define distance between Iso-Curves air-paths 01_Define Points 02_Absorbing Space 03_Distance between Air-paths 28 Acoustics by Addtive Manufacturing
  • 29. Design Steps r d Distance 01_Define Points Diameter: 02_Define “absorbing space” - 03_Define distance between 1-4cm 0.75cm < r < 2.5 cm Iso-Curves air-paths r d 04_Define position of sound 05_Draw Air-paths 06_Final outcome entrance of air-paths 04_Entrances 05_Air-Paths 06_Final Outcome 29 Acoustics by Addtive Manufacturing
  • 30. Distribution 400 Hz 500 Hz 750 Hz 1000 Hz 1500 Hz 500 Hz 1000 Hz 400 Hz 1500 Hz 750 Hz 30 Acoustics by Addtive Manufacturing
  • 31. Unit End Parts End Parts This part of This part of the tube is the tube is constant constant Middle Middle Point Point 31 Acoustics by Addtive Manufacturing
  • 32. Fabrication 1 Concepts 2 3 4 32 Acoustics by Addtive Manufacturing
  • 33. Perspective View 33 Acoustics by Addtive Manufacturing
  • 34. Perspective View 34 Acoustics by Addtive Manufacturing
  • 35. Visits 35 Acoustics by Addtive Manufacturing
  • 36. Collaborations 36 Acoustics by Addtive Manufacturing