WireBend-kit: A Computational Design and Fabrication Toolkit for Wirebending Custom 3D Wireframe Structures

Abstract: This paper introduces WireBend-kit, a desktop wirebending machine and computational design tool for creating 3D wireframe structures. Combined, they allow users to rapidly and inexpensively create custom 3D wireframe structures from aluminum wire. Our design tool is implemented in freely available software and allows users to generate virtual wireframe designs and assess their fabricability. A path-planning procedure automatically converts the wireframe design into fabrication instructions for our machine while accounting for material elasticity and kinematic error sources. The custom machine costs $293 in parts and can form aluminum wire into 3D wireframe structures through an ordered sequence of feed, bend, and rotate instructions. Our technical evaluation reveals our system's ability to overcome odometrically accumulating errors inherent to wirebending in order to produce accurate 3D structures from inexpensive hardware. Finally, we provide application examples demonstrating the design space enabled by Wirebend-kit.