Small Scale Plant Model

Spring 2013

The Spring 2013 team planned construction of a scale model of a 12 L/S AguaClara water treatment plant. The construction of this model was intended to educate and motivate individuals interested in the AguaClara water treatment process. The team edited AutoCAD drawings of the plant using the three-dimensional design software Rhinoceros; plant components were separated into individual planes and laid flat in templates. These pieces were optimized so that they would fit in a 12"x18" laser cutting area and aligned so that multiple pieces could be cut efficiently and at the same time. These finalized Rhinoceros files were then converted back into AutoCAD drawing files in preparation for laser cutting. The Rhinoceros files were also saved as PDFs so that the team could print paper templates to be used in the construction of the mock-up model. The mock-up's pieces were cut from chipboard using an X-ACTO knife and assembled with tape. The team finished certain pieces of the mock-up model this semester, including the main base, flocculator, filter, and filter inlet. The team also began work on other mock-up plant components, including the entrance tank and the staircase. Meanwhile, the Small Scale Plant Model team researched materials for building the final model, considering transparent and opaque Plexiglas, museum board, Plexiglas rod and tubing, and Plexiglue. After deliberation, it was decided that the entire model would be built in Plexiglas, and the team ordered and received 3 sheets of 12"x18" transparent Plexiglas, 6 sheets of 24"x24" white Plexiglas, and 1 sheet of 12"x12" blue Plexiglas. The team will laser cut these Plexiglas pieces through the school of Art, Architecture, and Planning, which offers a laser cutting service that is free to Cornell students.

Summer 2013

The Summer 2013 members plan on using the preliminary designs prepared by the Spring 2013 team in order to construct the final model. Our challenges include re-configuring AutoCAD templates to account for the thickness of the Plexiglas material. We intend on further researching methods to cut this Plexiglas into the necessary plant parts, such as using laser cutting processes or water-jet cutting processes. During assembly of the Plexiglas structure, we are going to create a detailed instruction manual documenting assembly specifics. Once the structure is complete, we can add plumbing components to the model. Towards the end of the summer we intend on evaluating our final structure to determine additional components that could possibly be created to supplement the plant model to increase understanding of the AguaClara project.

Fall 2013

The Fall 2013 team engaged a change of medium for the model: 3D printing. A method was designed to 3D print almost all of the componentry within laser cut plexiglass containers. AguaClara's 3D output model was evaluated in a more robust software Rhinoceros 5 in which students could manipulate the geometry and format it for 3D printing. This included re-formatting the objects to the correct material thickness at model scale and ensuring that components were closed polysurfaces with no naked or non-manifold edges. Structural considerations at model scale were also taken into account for both plexiglass and 3D printed objects. 3D printing was completed using Shapeways.com as well at at the Architecture Art and Planning department. All pieces were completed and cut and assembled; the model is almost completely finished. Considerations for moving forward include how scripting could engage the formatting requirements of 3D printing, how more of the model could be printed at once, and how the model could be simplified for representational purposes.