Faulkner Industrial may be a small and young company, but by adopting a lean 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 competitors. Due to this efficiency and affordability,
Faulkner provides greater value to clients by showcasing models throughout the design process, rather than just one model at the end.
Faulkner is small but passionate. "Faulkner Industrial is really just me and my Ultimaker 2 Extended +," Garrett admits. Nevertheless,
thanks to this fruitful partnership, the speed and quality of the models have begun to attract attention in the architectural world.
Garrett learned the basics of CAD in university and has experience working at a high-end architectural 3D printing service, which introduced him to his streamlined solution, focusing on desktop
3D printing rather than expensive industrial options.
By leveraging the development of design and work-ready software, as well as optimized practices in a high-volume production environment, he realized he could more directly serve a wider range of architects
rather than just larger firms.
Garrett says, "I found a route to produce high-quality models that far exceeded their original expectations and allowed them to apply designs from previous generations in a physical model space."
Garrett Faulkner making a model 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 leaves no time for iterative designs, which can lead to architects and clients taking a long time to see better results.
Even worse, Garrett says, "After the design is complete, models are often treated as an afterthought at the end of the design process - merely models to be shown to the client."
Designing a 3D object should include 3D models at various stages throughout the entire design process, allowing creators to place the models in a physical environment to see where improvements can be made and where things could be different.
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 series of 1:8 and 1:16 scale models, projects that even large service bureaus 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 one 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 that have been proven by expensive, high-end industrial manufacturing services.
Garrett says, "I make architectural models for architects in every aspect of the design process." Garrett adds, "Whether the design is in its initial stages,
when the design is complete, or during the design process. Faulkner strategically leverages the potential of desktop 3D printing every step of the way.
Large architectural site models from above
Part of how Faulkner exceeds client expectations is how he embraces new technologies.
Garrett says, "When new technologies or materials emerge, I am eager to use them, learn from them, and find ways to apply them at Faulkner Industrial."
Although there might be initial errors, he finds himself willing to embrace trial and error, which also gives him the necessary confidence to tackle many bidding challenges that other service agencies might face.
It was this courage to face rigorous manufacturing challenges that convinced his father, Greg Faulkner, chief architect at Faulkner Architects, to hire him to create production models for several high-profile residential and commercial space projects for the new company.
As with the design process, Garrett found that 3D printing manufacturing strategies and this kind of experimental testing allowed him to gain powerful printing solutions that 3D printer technicians would have taken years to discover.
Models printed by Faulkner Industrial
With rapid growth in product quality and speed, Faulkner Industrial can give Garrett more projects. Greg and his company understand that switching to desktop 3D printing has changed the range of services they can offer, making clients even happier.
Ultimaker Solutions for 3D Design
Choosing which desktop 3D printer and collaborating partners was no challenge for Garrett. Faster and more efficient time meant choosing a reliable and versatile printer.
Choosing Ultimaker was easy for me because it puts a new model on my desk every week,
pushing my designs further.
Having physical models available 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 selection 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 material choices, the open-source aspect, and its ability to print beautiful models for a fraction of the cost of larger machines."
Throughout the printer design, Garrett found the Ultimaker to be aesthetically pleasing, easily 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 Iteration 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 for improvements without spending too much time or money.
3D printing enables architects to modernize their design and iteration process.
For their filament needs, Faulkner Industrial uses Ultimaker PLA due to its excellent adhesion properties; an important feature when printing without water-soluble filament. Garrett says 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 printing time throughout the day, making Ultimaker's reliability another important feature. Design flexibility is also quite important, as some models need to utilize 3D printing to observe the structure before construction, a process that allows architects to observe different environmental locations with various lighting effects. This also benefits printing 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's use of 3D printing, Garrett found significant improvements in terms of 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 with previous methods using cork and balsa wood, greatly enhancing the iterative process experience.
Post-processing printed architectural models
Garrett also found that part quality was indistinguishable from larger, more expensive 3D printers. The ability to change nozzle sizes is very helpful in creating detailed prints, and after upgrading the printer, there were minimal extrusion issues.
Garrett says that throughout the workflow, the process of printing models in smaller parts and gluing them together forced the team to spend more time considering the overall design and what elements to emphasize in each print.
The Past, Present, and Future of Architectural Design
Garrett discovered that architects were surprised when one of his 3D printed models was produced so quickly after the file was given. Having been accustomed to physical models as a major investment of time and effort, often through tedious repairs or even remodeling, architects greatly appreciate the opportunity to make multiple revisions on an ongoing but perplexing project.
Garrett believes that in the future, by continuing to optimize the process for desktop 3D printing and related software, more architects can rely on services like his to lower the barriers to model production – leading to better design outcomes.
Garrett Faulkner working with 3D design
Finally seeing the shape of your work is very exciting, and it often validates an idea or directly points out errors. Garrett says it's important to work hard to learn this technology and be patient with the process.
When designers master 3D printing, diligent work pays off and can produce excellent models. By combining classical techniques with new technologies like 3D printing, architects have been able to push their designs to another level.
Garrett says, "The classic architectural model making method will always have a place in an architect's toolkit."
Trying to combine true craftsmanship with new 3D printing technology 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