Faulkner Industrial may be a small, young company, but by adopting a streamlined digital-to-physical pipeline and reliable Ultimaker desktop 3D
printers, they are able to deliver architectural scale models with less cost and turnaround time compared to their competitors. This efficiency and affordability
allow Faulkner to provide greater benefits to clients by producing models at various stages of the design process, rather than just one at the end.
Faulkner is small but passionate. "Faulkner Industrial is really just me and my Ultimaker 2 Extended +," Garrett admits. Nevertheless,
this fruitful partnership, along with the speed and quality of the models, has begun to attract attention in the architectural community.
Garrett learned the basics of CAD in university and has experience with high-end architectural 3D printing services, which led him to introduce his streamlined solution, primarily based on desktop
3D printing, rather than opting for high-cost industrial solutions.
By leveraging the development of design and work-preparation software, and optimized practices in a mass production environment, he realized he could more directly serve a wider range of architects
rather than just larger companies.
Garrett says, "I found a route to produce high-quality models that far exceeded their original expectations and allowed them to apply iterative designs in a
physical model space."
Garrett Faulkner making models with 3D printing
Garrett says: "Traditional architectural model making, using cork, balsa wood, and foam core, is very labor-intensive and expensive, and turnaround times can range from weeks
to months." It also doesn't leave time for iterative designs, which can lead to architects and clients taking a long time to see better results.
Worse, Garrett says: "Models are often treated as an afterthought at the end of the design process – merely for displaying to clients – after the design is complete."
Designing a 3D object should include 3D models at all stages of the entire design process, allowing creators to place the model in a physical environment
to see where improvements can be made and where things can be done differently.
Now, Garrett runs a successful business, combining his industrial manufacturing background with continuous exploration and innovation in desktop 3D printing. Garrett and
his Ultimaker have successfully executed a range of 1:8 and 1:16 scale models, projects that even large service agencies with decades of experience would consider
challenging.
From Traditional to Tech-Savvy
Faulkner Industrial can meet the demands and cost requirements of the large architectural community with a single Ultimaker 2 Extended +.
With the rapid development of digital design and desktop 3D printing technology, they have mastered the latest techniques, and they have learned the best tests, which
have been proven through high-cost, high-end industrial manufacturing services.
Garrett says: "I make architectural models for architects at every aspect of the design process." Garrett says: "Whether the design is in its initial stage,
when the design is complete, or during the design process, Faulkner can strategically leverage the potential of desktop 3D printing at every step.
Large architectural site model from above
Part of how Faulkner exceeds client expectations is how he embraces new technology.
Garrett says: "When new technologies or materials emerge, I'm eager to use them, learn from them, and find ways to apply them at Faulkner Industrial."
Although there were initial errors, he found himself willing to embrace trial and error, which also gave him the necessary confidence to tackle many challenges that other service agencies might face
when bidding for projects.
It was this courage to face rigorous manufacturing challenges that convinced his father, Greg Faulkner, principal architect at Faulkner Architects, to hire him to create production models for several
high-profile residential and commercial space projects for his new company.
As with the design process, Garrett found that 3D printing manufacturing strategies and this experimental testing allowed him to gain powerful printing solutions that 3D printer technicians
have discovered over many years.
Faulkner Industrial printed models
With the rapid increase in product quality and speed, Faulkner Industrial was able to give Garrett more projects. Greg and his company understood that switching to desktop 3D
printing changed the scope of services they could offer, making clients even happier.
Ultimaker Solutions for 3D Design
Choosing which desktop 3D printer and collaborator to use was not a challenge for Garrett. Faster and more efficient turnaround times meant he needed a reliable and versatile
printer.
Choosing Ultimaker was easy for me because it allows me to have a new model on my desk every week,
pushing my designs further.
Having physical models days in advance greatly impresses clients, which is invaluable when communicating with non-technical clients.
3D models printed with Ultimaker
Given his background in high-end additive manufacturing solutions, Garrett initially thought he might eventually invest in an industrial-grade printer, but the size, cost, and
strict material choices all pushed him towards sticking with the affordable and user-friendly Ultimaker.
Garrett says: "I once had the opportunity to use an Ultimaker in a maker community in San Francisco and found it to be a versatile consumer-grade machine. I was impressed by the range of materials
available, the open-source aspect, and its ability to print beautiful models for a fraction of the cost of larger machines."
Throughout the printer's design, Garrett found the Ultimaker to be aesthetically pleasing, portable, and proven to be very valuable for travel.
He also appreciates the open-source aspect of Ultimaker, which allows Faulkner Industrial to upgrade the printer when necessary.
The Perfect Design and Iterative Process
Garrett believes that the additive manufacturing process has the potential to transform the architecture and design industries. By being able to create 3D printed models on a small scale, architects can meet with colleagues and
clients, gather collaborative feedback, and make quick changes to improvements without spending too much time or money.
3D printing modernizes how architects approach design and the iterative process.
For their filament needs, Faulkner Industrial uses Ultimaker PLA because of its excellent adhesion properties; an important feature when printing with non-water-soluble filaments.
Garrett says that Ultimaker PLA provides consistent results that clients appreciate, which is crucial for producing many models.
Some of Faulkner Industrial's larger models require 100 to 300 hours of continuous printing, making Ultimaker's reliability another important feature. Design flexibility is also critical,
as some models need to utilize 3D printing to observe the structure before construction, a process that allows architects to observe different environments in various lighting effects.
This also helps in printing models for different locations, providing clients with basic models to choose from when considering the overall design.
Saving Time and Money is Paramount
Among all the benefits of Faulkner Industrial using 3D printing, Garrett finds significant improvements in cost, time, quality, and workflow.
Garrett says: "Due to the small initial investment and lower model production costs, reducing costs is important, allowing us to produce more models. Printing time is
less than the previous method of making models with cork and balsa wood, greatly enhancing the iterative process experience.
Post-processing printed architectural models
Garrett also found that the part quality was indistinguishable from larger, more expensive 3D printers. Being able to change nozzle sizes is helpful when creating detailed prints,
with minimal extrusion issues after upgrading the printer.
Garrett says that throughout the workflow, the process of printing models in smaller sections and gluing them together forces the team to spend more time considering the overall design
and which elements to emphasize during each printing process.
The Past, Present, and Future of Architectural Design
Garrett found that architects were surprised when one of his 3D printed models could be produced so quickly after receiving the files. Accustomed to physical models
being a major investment of time and effort, often requiring tedious repairs or even remodels, architects greatly appreciate the opportunity to make multiple revisions
to ongoing projects that they may be struggling with.
Garrett believes that by continuing to optimize the process for desktop 3D printing and related software in the future, more architects can rely on services like his to lower
the barriers to model production – achieving better design outcomes.
Garrett Faulkner working with 3D design
Finally seeing the physical form of your work is very exciting; it often validates an idea or directly points out errors. Garrett says it's important to diligently learn this
technology and be patient with the process.
When designers master 3D printing, hard work pays off, and excellent models can be produced. By combining classic techniques with new technologies like 3D printing,
architects have been helped to take their designs to the next level.
Garrett says: "Classic architectural model-making methods will always have a place in an architect's toolkit."
The attempt to combine traditional techniques with new 3D printing technologies has laid the foundation for these amazing architectural models.
Original source: https://ultimaker.com/en/stories/51042-faulkner-industrial-3d-printing-the-future-of-architectural-design