Rib Layout Generation for Cast Metal Plates

This research explores how to parametrically generate rib layouts accounting for both structural constraints and metal casting constraints. An algorithm was developed that takes as its input the boundary and support positions. Parametric rib layouts corresponding to these inputs are generated based on curve networks. Curve networks are composed of two sets of curves:Isocurves (left plots, gray lines) that derive from the distance field of the support position and Agent-Based Curves (left plots, cyan lines) that are perpendicular to the isocurves and depart from the support point. The density of the curve network is parametrically adjustable, as are the depth and width of the ribs along the curves. 

This computational approach was tested on a 1:1 metal cast table prototype. The method was expanded to include casting constraints. The circular support positions also serve as cast pouring locations for molten metal. Aluminum flow constraints were factored into rib depth and width generation, and casting constraints inform the density of the ribs. The design reduces weight and material consumption by distributing and aligning material along the flow path of forces while at the same time accounting for the flow physics of molten metal during the casting process. Thus, the computational design model integrates structural optimization and casting constraints.