Designer Chair With Intelligent Internal Structure


Novi, Mich., March 14th, 2007 - Stress analysis and structure manipulation software developed by Dr. Siavash Mahdavi at University College London has enabled world-renowned designer Assa Ashuash to create Osteon, a chair that combines his artistic flair with precise mechanical characteristics. They include lightness, extra strength in areas that are under greatest stress, and minimum material usage. In the past, this design would have been impossible to build, but modern rapid manufacturing technology came to the rescue. Osteon was made a reality by taking horizontal slices through a 3D computer-aided design (CAD) model. The resulting data was then used to drive a laser-sintering machine, which created the product by fusing successive layers of plastic powder.

Explained Mr. Ashuash, "The Osteon Chair is the first to be designed using a combination of 3D production tools and artificial intelligence. The software knows where to create sufficient support, rather like the evolution of the biological structure and mechanism of bone. The chair is grown in free space with a 'DNA' code containing all the information required to ensure that the object will transform perfectly from a virtual design into a 3D object that achieves optimum strength while maintaining the desired visual aesthetic."

Dr. Mahdavi, managing director of Complex Matters, a spin-off from his research at University College London, stated, "Our software works rather like finite element analysis in reverse. We formulate an ideal set of end results as the starting point and work backwards to create the optimal structure required to achieve that goal."

"In this project, our software imported the CAD model of the chair and all of the relevant parameters, including the average person's weight and the maximum permissible amount of flex at various points around the chair's structure," explained Dr. Mahdavi. "Artificial intelligence in the software then worked on the data, identifying stress points in the chair, morphing the original design slightly to satisfy the physical requirements, and generating a custom lattice that minimised the amount of plastic used yet incorporating the necessary strength and mechanical characteristics. An external skin was incorporated over a majority of the structure for aesthetics and user comfort."

The Osteon took physical form with laser-sintering technology. The virtual chair design was split into sections so that each could be grown within the 27.5 x 15 x 23 inch build envelope of an EOSINT P 700 laser-sintering machine.
Commented Stuart Jackson, EOS' regional manager for the UK and Ireland, "It has been fascinating to work with Assa and Siavash on the Osteon Chair project and to see the realisation of a beautiful, yet practical, piece of furniture. It is noteworthy that our rapid manufacturing technology lends itself to the creation of customized products. So, if a person is heavier than average or wants greater stiffness in the lumbar region, for example, the chair could be modified to suit."

"With Dr. Mahdavi's new software, the possibilities of laser-sintering in the arts and industry are endless, and applications are already being found in engineering, construction and medicine," Jackson concluded.

About EOS

EOS was founded in 1989 and is today the world leading manufacturer of laser-sintering systems. Laser-sintering is the key technology for e-Manufacturing, the fast, flexible and cost-effective production of products, patterns or tools. The technology manufactures parts for every phase of the product life cycle, directly from electronic data. Laser-sintering accelerates product development and optimizes production processes. EOS completed its last business year on September 30th, 2006 with laser-sintering revenues of 52.3 million Euro and thus continues its ongoing growth.

Homepage: www.eos.info

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