AirForce: Personal Fabrication of Large-Scale, Load-Bearing Animatronics Structures from a Single Tube We present a fabrication system called AirForce that allows users to create large-scale, load-bearing animated structures from a single inflatable tube. AirForce builds on the personal fabrication of animated truss structures, based on which it replaces not only the static elements with tube, but also introduces tube-based actuators that integrate with that same tube. This ‘single-tube’ design affords efficient single-person assembly, excellent power-to-weight ratio, easy transport and setup, and 100% material reuse. We show three variants of actuators: buckling actuators for pushing, muscle actuators for pulling, and telescoping actuators for large forces. Our blender plugin enables users to place actuators in structures and export instructions for efficient fabrication. We demonstrate a 6DOF motion platform that lifts humans and an 8m high animatronic T-rex that animates with 3DOF, enabled by custom hardware components. In our technical evaluation, the three actuators delivered 480N, 1420N, and 2330N peak forces, respectively.2026LRLukas Rambold et al.Hasso Plattner InstituteDesktop 3D Printing & Personal FabricationShape-Changing Materials & 4D PrintingCircuit Making & Hardware PrototypingCHI
SustainaPrint: Making the Most of Eco-Friendly FilamentsWe present SustainaPrint, a system for integrating eco-friendly filaments into 3D printing without compromising structural integrity. While biodegradable and recycled 3D printing filaments offer environmental benefits, there is a trade-off in using them as they may suffer from degraded or unpredictable mechanical properties, which can limit their use in load-bearing applications. SustainaPrint addresses this by strategically assigning eco-friendly and standard filaments to different regions of a multi-material print—reinforcing the areas that are most likely to break with stronger material while maximizing the use of sustainable filament elsewhere. As eco-friendly filaments often do not come with technical datasheets, we also introduce a low-cost, at-home mechanical testing toolkit that enables users to evaluate filament strength before deciding if they want to use that filament in our pipeline. We validate SustainaPrint through real-world fabrication and mechanical testing, demonstrating its effectiveness across a range of functional 3D printing tasks.2025MPMaxine Perroni-Scharf et al.Desktop 3D Printing & Personal FabricationCustomizable & Personalized ObjectsSustainable HCIUIST
Mallet-Based Assembly: Enabling Load-Bearing Laser-Cut ModelsLaser cutting has a long tradition of building load-bearing 3D objects based on box joints and T-joints, as these joints are naturally robust against compression and shearing. Achieving robustness against tension, however, is challenging. One presumed solution is to make all joints extremely tight, to the point where they can only be assembled using a mallet. However, our survey found that making joints tight can cause models to break during assembly. In this paper, we identify the 10 underlying issues and present techniques for overcoming them: by extending parts with what we call scaffolding or by adjusting the models’ assembly order, so as to bypass states that are subject to these issues. Based on our user study and analysis of laser-cut models, scaffolding speeds up assembly for an average of 14% of the assembly operations per model, which in turn gives an average of 1.3x speed-up per model, and 70% of the models would benefit from the adjusted assembly order, that in the absence of such, would require higher assembly effort.2025SKShohei Katakura et al.Laser Cutting & Digital FabricationUIST
AirTied: Automatic Personal Fabrication of Truss StructuresWe present AirTied, a device that fabricates truss structures in a fully automatic fashion. AirTied achieves this by un-rolling a 20cm-wide inflatable plastic tube and tying nodes into it. AirTied creates nodes by holding onto a segment of tube, stacking additional tube segments on top of it, tying them up, and releasing the result. The resulting structures are material efficient and light as well as sturdy, as we demonstrate by creating a 6m-tower. Unlike the prior art, AirTied requires no scaffolding and no building blocks, bringing automated truss construction into the reach of personal fabrication.2023LRLukas Rambold et al.Desktop 3D Printing & Personal FabricationLaser Cutting & Digital FabricationShape-Changing Materials & 4D PrintingUIST
Kerfmeter: Automatic Kerf Calibration for Laser Cutting We present Kerfmeter, a hardware + software device that automatically determines how much material the laser cutter burns off, also known as kerf. Its knowledge about kerf allows Kerfmeter to make the joints of laser cut 3D models fit together with just the right tension, i.e., loose enough to allow for comfortable assembly, yet tight enough to hold parts together without glue—all this without user interaction. Kerfmeter attaches to the head of a laser cutter and works as follows: when users send a model to the laser cutter, Kerfmeter intercepts the job, injects a brief calibration routine that determines kerf, dilates the cutting plan according to this kerf, and then proceeds to fabricate the cutting plan. During the calibration routine, Kerfmeter cuts a 2cm Archimedean spiral and uses a motor to rotate it in place until it jams against the surrounding material; the angle at which the spiral jams allows Kerfmeter to infer kerf. The calibration process takes about 20s, which is >10x faster than traditional, manual kerf calibration, while also eliminating the need for expertise. In our technical evaluation, Kerfmeter produced functioning press fit joints reliably at a precision comparable to traditional manual kerf strips. Kerfmeter makes it easy to sample repeatedly; we demonstrate how this allows boosting precision past any traditional kerf strip.2023SKShohei Katakura et al.Hasso Plattner Institute, Hasso Plattner InstituteLaser Cutting & Digital FabricationCircuit Making & Hardware PrototypingCHI
HingeCore: Laser-Cut Foamcore for Fast AssemblyWe present HingeCore, a novel type of laser-cut 3D structure made from sandwich materials, such as foamcore. The key design element behind HingeCore is what we call a finger hinge, which we produce by laser-cutting foamcore “half-way”. The primary benefit of finger hinges is that they allow for very fast assembly, as they allow models to be assembled by folding and because folded hinges stay put at the intended angle, based on the friction between fingers alone, which eliminates the need for glue or tabs. Finger hinges are also highly robust, with some 5mm foamcore models withstanding 62kg. We present HingeCoreMaker, a stand-alone software tool that automatically converts 3D models to HingeCore layouts, as well as an integration into a 3D modeling tool for laser cutting (Kyub [7]). We have used Hinge-CoreMaker to fabricate design objects, including speakers, lamps, and a life-size bust, as well as structural objects, such as functional furniture. In our user study, participants assembled HingeCore layouts 2.9x faster than layouts generated using the state-of-the-art for plate-based assembly (Roadkill [1]).2022MAMuhammad Abdullah et al.Shape-Changing Interfaces & Soft Robotic MaterialsLaser Cutting & Digital FabricationUIST
FoolProofJoint: Reducing Assembly Errors of Laser Cut 3D Models by Means of Custom Joint Patterns We present FoolProofJoint, a software tool that simplifies the assembly of laser-cut 3D models and reduces the risk of erroneous assembly. FoolProofJoint achieves this by modifying finger joint patterns. Wherever possible, FoolProofJoint makes similar looking pieces fully interchangeable, thereby speeding up the user’s visual search for a matching piece. When that is not possible, FoolProofJoint gives finger joints a unique pattern of individual finger placements so as to fit only with the correct piece, thereby preventing erroneous assembly. In our benchmark set of 217 laser-cut 3D models downloaded from kyub.com, FoolProofJoint made groups of similar looking pieces fully interchangeable for 65% of all groups of similar pieces; FoolProofJoint fully prevented assembly mistakes for 97% of all models.2022KPKeunwoo Park et al.Hasso Plattner InstituteLaser Cutting & Digital FabricationCHI
Trusscillator: a System for Fabricating Human-Scale Human-Powered Oscillating DevicesTrusscillator is an end-to-end system that allows non-engineers to create human-scale human-powered devices that perform oscillatory movements, such as playground equipment, workout devices, and interactive kinetic installations. While recent research has been focusing on generating mechanisms that produce specific movement-path, without considering the required energy for the motion (kinematic approach), Trusscillator supports users in designing mechanisms that recycle energy in the system in the form of oscillating mechanisms (dynamic approach), specifically with the help of coil-springs. The presented system features a novel set of tools tailored for designing the dynamic experience of the motion. These tools allow designers to focus on user experience-specific aspects, such as motion range, tempo, and effort while abstracting away the underlying technicalities of eigenfrequencies, spring constants, and energy. Since the forces involved in the resulting devices can be high, Trusscillator helps users to fabricate from steel, by picking out appropriate steal springs, generating part lists, and by producing stencils and welding jigs that help weld with precision. To validate our system, we designed, built, and tested a series of unique playground equipment featuring 2-4 degrees of movement.2021RKRobert Kovacs et al.Desktop 3D Printing & Personal FabricationShape-Changing Materials & 4D PrintingUIST
AutoAssembler: Automatic Reconstruction of Laser-Cut 3D Models Recent research showed how to import laser cut 3D models encoded in the form of 2D cutting plans into a 3D editor (assembler^3), which allows users to perform parametric manipulations on such models. In contrast to assembler^3 , which requires users to perform this process manually, we present autoAssembler, which performs this process automatically. AutoAssembler uses a beam search algorithm to search possible ways of assembling plates. It uses joints on these plates to combine them into assembly candidates. It thereby preferably pursues candidates (1) that have no intersecting plates, (2) that fit into a small bounding box, (3) that use plates whose joints fit together well, (4) that do not add many unpaired joints, (5) that make use of constraints posed by other plates, and (6) that conform to symmetry axes of the plates. This works for models that have at least one edge joint (finger or t-joint). In our technical evaluation, we imported 66 models using autoAssembler. AutoAssembler assembled 79% of those models fully automatically; another 18% of models required on average 2.7 clicks of post-processing, for an overall success rate of 97%.2021TRThijs Roumen et al.Laser Cutting & Digital FabricationShape-Changing Materials & 4D PrintingUIST
Roadkill: Nesting Laser-Cut Objects for Fast AssemblyWe present Roadkill, a software tool that converts 3D models to 2D cutting plans for laser cutting—such that the resulting layouts allow for fast assembly. Roadkill achieves this by putting all relevant information into the cutting plan: (1) Thumbnails indicate which area of the model a set of parts belongs to. (2) Parts with exposed finger joints are easy to access, thereby suggesting to start assembly here. (3) Openings in the sheet act as jigs, affording assembly within the sheet. (4) Users continue assembly by inserting what has already been assembled into parts that are immediately adjacent or are pointed to by arrows. Roadkill maximizes the number of joints rendered in immediate adjacency by breaking down models into “subassemblies.” Within a subassembly, Roadkill holds the parts together using break-away tabs. (5) Users complete subassemblies according to their labels 1, 2, 3…, following 1 > 1 links to insert subassemblies into other subassemblies, until all parts come together. In our user study, Roadkill allowed participants to assemble layouts 2.4 times faster than layouts generated by a traditional pair-wise labeling of plates.2021MAMuhammad Abdullah et al.Laser Cutting & Digital FabricationCircuit Making & Hardware PrototypingUIST
FastForce: Real-Time Reinforcement of Laser-Cut StructuresWe present fastForce, a software tool that detects structural flaws in laser cut 3D models and fixes them by introducing additional plates into the model, thereby making models up to 52x stronger. By focusing on a specific type of structural issue, i.e., poorly connected sub-structures in closed box structures, fastForce achieves real-time performance (10^6x faster than finite element analysis, in the specific case of the wheelbarrow from Figure 1). This allows fastForce to fix structural issues continuously in the background, while users stay focused on editing their models and without ever becoming aware of any structural issues. In our study, six of seven participants inadvertently introduced severe structural flaws into the guitar stands they designed. Similarly, we found 286 of 402 relevant models in the kyub [1] model library to contain such flaws. We integrated fastForce into a 3D editor for lasercutting (kyub) and found that even with high plate counts fastForce achieves real-time performance.2021MAMuhammad Abdullah et al.Hasso Plattner InstituteLaser Cutting & Digital FabricationCircuit Making & Hardware PrototypingCHI
Assembler^3: 3D Reconstruction of Laser-cut ModelsWe present assembler^3 a software tool that allows users to perform 3D parametric manipulations on 2D laser cutting plans. Assembler^3 achieves this by semi-automatically converting 2D laser cutting plans to 3D, where users modify their models using available 3D tools (kyub), before converting them back to 2D. In our user study, this workflow allowed users to modify models 10x faster than using the traditional approach of editing 2D cutting plans directly. Assembler^3 converts models to 3D in 5 steps: (1) plate detection, (2) joint detection, (3) material thickness detection, (4) joint matching based on hashed joint "signatures", and (5) interactive reconstruction. In our technical evaluation, assembler^3 was able to reconstruct 100 of 105 models. Once 3D-reconstructed, we expect users to store and share their models in 3D, which can simplify collaboration and thereby empower the laser cutting community to create models of higher complexity.2021TRThijs Roumen et al.Hasso Plattner InstituteLaser Cutting & Digital FabricationCircuit Making & Hardware PrototypingCHI
Kerf-Canceling Mechanisms: Making Laser-Cut Mechanisms Operate across Different Laser CuttersGetting laser-cut mechanisms, such as those in microscopes, robots, vehicles, etc., to work, requires all their components to be dimensioned precisely. This precision, however, tends to be lost when fabricating on a different laser cutter, as it is likely to remove more or less material (aka “kerf”). We address this with what we call kerf-canceling mechanisms. Kerf-canceling mechanisms replace laser-cut bearings, sliders, gear pairs, etc. Unlike their traditional counterparts, however, they keep working when manufactured on a different laser cutter and/or with different kerf. Kerf-canceling mechanisms achieve this by adding an additional wedge element per mechanism. We have created a software tool KerfCanceler that locates traditional mechanisms in cutting plans and replaces them with their kerf-canceling counterparts. We evaluated our tool by converting 17 models found online to kerf-invariant models; we evaluated kerf-canceling bearings by testing with kerf values ranging from 0mm and 0.5mm and find that they perform reliably independent of this kerf.2020TRThijs Jan Roumen et al.Laser Cutting & Digital FabricationUIST
Understanding Metamaterial MechanismsIn this paper, we establish the underlying foundations of mechanisms that are composed of cell structures---known as metamaterial mechanisms. Such metamaterial mechanisms were previously shown to implement complete mechanisms in the cell structure of a 3D printed material, without the need for assembly. However, their design is highly challenging. A mechanism consists of many cells that are interconnected and impose constraints on each other. This leads to unobvious and non-linear behavior of the mechanism, which impedes user design. In this work, we investigate the underlying topological constraints of such cell structures and their influence on the resulting mechanism. Based on these findings, we contribute a computational design tool that automatically creates a metamaterial mechanism from user-defined motion paths. This tool is only feasible because our novel abstract representation of the global constraints highly reduces the search space of possible cell arrangements.2019AIAlexandra Ion et al.Hasso Plattner Institute, University of PotsdamShape-Changing Materials & 4D PrintingPrototyping & User TestingCHI
SpringFit: Joints and Mounts That Fabricate On Any Laser CutterJoints are crucial to laser cutting as they allow making three-dimensional objects; mounts are crucial because they allow embedding technical components, such as motors. Unfortunately, mounts and joints tend to fail when trying to fabricate a model on a different laser cutter or from a different material. In our survey of 200 models found online, 65% of models we downloaded from an online re-pository did not fabricate properly because of this. We trace this issue back to the way mounts and joints hold objects in place, which is by forcing them into is slightly smaller openings. Such “press fit” mechanisms unfortunately are susceptible to the small changes in diameter that occur when switching to a machine that removes more or less material (“kerf”), as well as to the changes in stiffness, as they occur when switching materials. Thus the issue with downloaded models. We present a software tool called springFit that resolves this problem by replacing the problematic press fit-based mounts with what we call canti¬lever-based mounts and joints. A cantilever spring is simply a long thin piece of material that pushes against the object to be held. Unlike press fits, cantilever springs are robust against variations in kerf and material; they can even handle very high varia-tions, simply by using longer springs. SpringFit converts entire models by replacing all contained mounts, notch joints, finger joints, and t-joints. In our technical evalua-tion springFit successfully converted 11/14 models from the web which fabricated in acrylic and wood and across different laser cutters. SpringFit is a first step towards what we want to call “portable” laser cutting.2019TRThijs Roumen et al.Laser Cutting & Digital FabricationCircuit Making & Hardware PrototypingUIST
Kyub: A 3D Editor for Modeling Sturdy Laser-Cut ObjectsWe present an interactive editing system for laser cutting called kyub. Kyub allows users to create models efficiently in 3D, which it then unfolds into the 2D plates laser cutters expect. Unlike earlier systems, such as FlatFitFab, kyub affords construction based on closed box structures, which allows users to turn very thin material, such as 4mm plywood, into objects capable of withstanding large forces, such as chairs users can actually sit on. To afford such sturdy construction, every kyub project begins with a simple finger-joint "boxel"—a structure we found to be capable of withstanding over 500kg of load. Users then extend their model by attaching additional boxels. Boxels merge automatically, resulting in larger, yet equally strong structures. While the concept of stacking boxels allows kyub to offer the strong affordance and ease of use of a voxel-based editor, boxels are not confined to a grid and readily combine with kuyb's various geometry deformation tools. In our technical evaluation, objects built with kyub withstood hundreds of kilograms of loads. In our user study, non-engineers rated the learnability of kyub 6.1/7.2019PBPatrick Baudisch et al.Hasso Plattner Institute, University of PotsdamLaser Cutting & Digital FabricationCircuit Making & Hardware PrototypingCHI
RoMA: Interactive Fabrication with Augmented Reality and a Robotic 3D PrinterWe present the Robotic Modeling Assistant (RoMA), an interactive fabrication system providing a fast, precise, hands-on and in-situ modeling experience. As a designer creates a new model using RoMA AR CAD editor, features are constructed concurrently by a 3D printing robotic arm sharing the same design volume. The partially printed physical model then serves as a tangible reference for the designer as she adds new elements to her design. RoMA’s proxemics-inspired handshake mechanism between the designer and the 3D printing robotic arm allows the designer to quickly interrupt printing to access a printed area or to indicate that the robot can take full control of the model to finish printing. RoMA lets users integrate real-world constraints into a design rapidly, allowing them to create well-proportioned tangible artifacts or to extend existing objects. We conclude by presenting the strengths and limitations of our current design.2018HPHuaishu Peng et al.Cornell University3D Modeling & AnimationDesktop 3D Printing & Personal FabricationLaser Cutting & Digital FabricationCHI
DualPanto: A Haptic Device that Enables Blind Users to Continuously Interact with Virtual WorldsWe present a new haptic device that enables blind users to continuously interact with spatial virtual environments that contain moving objects, as is the case in sports or shooter games. Users interact with DualPanto by operating the me handle with one hand and by holding on to the it handle with the other hand. Each handle is connected to a pantograph haptic input/output device. The key feature is that the two handles are spatially registered with respect to each other. When guiding their avatar through a virtual world using the me handle, spatial registration enables users to track moving objects by having the device guide the output hand. This allows blind players of a 1-on-1 soccer game to race for the ball or evade an opponent; it allows blind players of a shooter game to aim at an opponent and dodge shots. In our user study, blind participants reported very high enjoyment when using the device to play (6.5/7).2018OSOliver Schneider et al.Vibrotactile Feedback & Skin StimulationAccessible GamingUIST
iTurk: Turning Passive Haptics into Active Haptics by Making Users Reconfigure Props in Virtual RealityWe present a system that complements virtual reality experiences with passive props, yet still allows modifying the virtual world at runtime. The main contribution of our system is that it does not require any actuators; instead, our system employs the user to reconfigure and actuate otherwise passive props. We demonstrate a foldable prop that users reconfigure to represent a suitcase, fuse cabinet, railing, and a seat. A second prop, suspended from a long pendulum, not only stands in for inanimate objects, but also for objects that move and demonstrate proactive behavior, such as a group of flying droids that physically attack the user. Our approach conveys a sense of a living, animate world, when in reality the user is the only animate entity present in the system, complemented with only one or two physical props. In our study, participants rated their experience as more enjoyable and realistic than a corresponding no-haptics condition.2018LCLung-Pan Cheng et al.Hasso Plattner InstituteShape-Changing Interfaces & Soft Robotic MaterialsFull-Body Interaction & Embodied InputCHI
Scenograph: Fitting Real-Walking VR Experiences into Various Tracking VolumesWhen developing a real-walking virtual reality experience, designers generally create virtual locations to fit a specific tracking volume. Unfortunately, this prevents the resulting experience from running on a smaller or differently shaped tracking volume. To address this, we present a software system called Scenograph. The core of Scenograph is a tracking volume-independent representation of real-walking experiences. Scenograph instantiates the experience to a tracking volume of given size and shape by splitting the locations into smaller ones while maintaining narrative structure. In our user study, participants’ ratings of realism decreased significantly when existing techniques were used to map a 25m2 experience to 9m2 and an L-shaped 8m2 tracking volume. In contrast, ratings did not differ when Scenograph was used to instantiate the experience.2018SMSebastian Marwecki et al.Immersion & Presence ResearchUIST