DIGITAL DESIGN + FABRICATION SLEEPING POD SM1, 2016 Kwan Chin Ching Cathy 713458 Michelle James, Group One
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CONTENT M1 IDEATION 1.1 Measured Drawings + Rhino 1.2 System Analysis + Volume 1.3 Sketch Design Proposal
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M2 DESIGN 2.1 Design Development 2.2 Design Proposal V.1 #1 #2 #3 2.3 Precedent Research 2.4 Design Proposal V.2 2.5 Prototype V.1 + Testing Effect
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M3 FABRICATION 3.1 Fabrication Introduction 3.2 Design Development + Prototype V.2 Design Development + Bolt n Clamp 3.3 Design Development + Prototype V.3 3.4 Design Development + Prototype V.4 3.5 Final Prototype Connection Optimisation 3.6 Final Digital Model 3.7 Fabrication Sequence 3.8 Assembly Drawing 3.8 Final Sleeping Pod
M4 REFLECTION
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APPENDIX 5.1 Credit 5.2 Bibliography
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M1 IDEATION 6
MEASURED DRAWINGS
PLAN
ISOMETRIC VIEW SCALE 1:2
SCALE 1:2
ELEVATION- FRONT SCALE 1:1 7
RHINO MODEL
PLAN
ELEVATION- FRONT
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ISOMETRIC VIEW
Many different methods were describe in 300 Years of Industrial Design (2000), and my chosen object was a expanding folder. It is square in shape with only straight lines, therefore I could use a ruler to measure all the lengths and draw on the paper easily. Most of the drawings are 1:2 and some of them are 1:1.
Although I could measure all the lengths easily it is hard for me to draw the isometric view without any reference. I took a photo of the opened expanding folder in an angle similar to isometric view for a better understanding of the shape. Then I drew it on tracing paper with an isometric grid print paper as an underlay.
Once I had all of the measurements and drawings I used Pictureframe in Rhino them into Rhino for me to trace out the shape easily. Then I used Gumball to rotate all of the pieces into the desired position. After that I used edge surface, rotate and mirror to create the whole folder.
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SYSTEM ANALYSIS
The expanding folder is mainly formed by two elements: the constraining folder and the cover. Dividers are added at the end to create compartments. The constraining folder is created by only one plane. The plane is folded evenly in opposite directions to form a zigzag pattern. The plane then become expandable which can change in length easily.
The whole plane is 150 x 420 mm. It is folded into 28 small fragments ( 150 x 15 mm)
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The cover is the one that holds and controls the constraining folder. The two ends of the constrained plane stick to the cover and a volume is created. The volume of the folder varies in the angle of the cover opened. Enric, Carme (1988/1991)’s drawing methods is used below to show the system of this folder are shown. When the folder is opened, the bottom of the flexible part compress and forms a fan shape.
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VOLUME - SKETCH MODEL
The main idea of my reconfigured model is the flexible part of the expanding folder. The original version is simple but only travels in one direction. I tried to add diagonal lines to each column and reverse fold them. By doing so in two directions and combine them with the normal folded part, a curve is created. Volume is also created under the model using only one paper. The whole thing can still compress together as one thinner form and this pattern also strengthened the paper itself.
PLAN
ELEVATION
FOLD
EXPAND
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DETAIL
SKETCH DESIGN PROPOSAL DESIGN#1 This design is inspired by hedgehog’s sting. It can cover up all the facial features and also the whole head down to shoulder area. Somer (1969) mentioned that personal varies according to the location and action and for sleeping the most concern area should be the head area. which provides users the maximum protection from the others while sleeping.
DESIGN#2 This design is inspired by plant. Area in front of a person’s face is the most sensitive area that requires more protection. This design can hide and cover user’s facial features with minimum components.
DESIGN#3 This model is inspired by clown neck ruffle. This design aim to keep others from a suitable distance without covering user’s face. This neck ruffle can maintain certain distance and allow user looks and breathes normally
On this module I have learnt that personal space is something that invisible yet important to our sense of security. And it is interesting how our personal space can changes according to our situations and the surrounding objects. I had discover the how my personal space affect my daily live. I come from a crowded city and I have smaller personal space (comfort zone) relatively.
Different measuring methods are introduced in this module for more accurate measurement. Although for expanding folder ruler can be used, these methods can help me to measure and draw out helpful diagrams easily in the future.
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M2 DESIGN PARTNER: FAHIM MARIAN
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DESIGN DEVELOPMENT We tried to find out the similarities of our sketch designs and in conclusion we were both interested in ADJUSTABLE sleeping pod design. Therefore we experimented with different folding patterns and see which one suits our design. PORTABLE was another main ideas that we were achieving in our previous sketch designs since we believed it would be much convenient for student to carry it to school. At the end we also agreed that we should have a DYNAMIC design to show the movement of the chosen pattern while using. We took photos of different sleeping positions to see all the possible ways of how a person can sleep on a chair. We found that there were mainly two types of sleeping method: lay down on the chair using the chair’s back as support and slept on the table with your arms to support the head. We drew out the shape of personal space roughly and found that the shape of the personal space for each sleeping position was actually quit similar. Therefore we wanted to make a multifunctional design that can fit both sleeping positions.
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DESIGN PROPOSAL V.1 #1
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We tried to trace out the shape of personal space we got from the sleeping positions and lofted it in Rhino to come up with this sketch design. This sleeping pod design can cover they whole upper body to provide enough privacy and sense of security. After that we combined the folding pattern into this design.
FRONT
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SIDE
This design can be folded like a stick. When the user opens it the shorter part will move inward and the longer part will push outward to form the curve. The side view explains the moving directions of two parts and the front view explains how the curve is created. It is designed for users to sleep with different poses. When the user lies down on the back of the chair the device covers the user's face and provides support for the neck. The bangs on both side can surround and tie to the chair. When the user tries to sleep on their arms this device can cover the back to provide a sense of security. User can wear this design using the bangs. Holes are created to allow light and air pass through.
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DESIGN PROPOSAL V.1 #2
TOP We also tried to design a smaller size sleeping pod which just covered the most important personal space area (head). It is portable and lightweight which makes it more convenient to carry around.
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FRONT
SIDE
PERSPECTIVE
The pattern of this design was taken from the 3D flower origami. We took a fragment of the shape (one member) and modified it then repeated it to create a different form.
This design can be compressed to sit on the neck and it can expand when needed. It respects personal space as it creates its own space within its shape. Also, this can be used in different sleeping positions as it does not limit the body movements.
Images on the left are the prototypes of different folding patterns that give similar effects when they are compressed then expanded. These folds are mainly build on the reverse fold pattern but the angles and directions vary.
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DESIGN PROPOSAL V.1 #3
We studied the movement of this origami piece and how it changed from one form to another. It moved in 3D circular motion in order to flip. We tried to connect more than one of them together to create a circular shape but it did not work as it lost its 3D rotation. We found that the only way to solve this issue was to lose the 3D movement as it could only move like 2D object open and close) if they were connected.
On the right hand side of the page is the model when we tried to connect a number of the origami pieces together to create structure. However, it did not work because the movement of each piece were not happening due to the fixed part (the part connecting to the two pieces). Also, there were too many hollow parts in-between the pieces which would be hard to cover .
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PRECEDENT RESEARCH VEASYBLE
by GAIA (2009)
This precedent influences our design as they have similar concept. Our idea is to convert from 2D to 3D form and the opposite which is quite similar to the precedent. We also liked how the precedent intelligently used the shape to make the design portable and easy to carry around. This is what we are aiming to achieve while developing our ideas.
The whole design is created by reverse fold. It can be folded and compress into a bag shape when not used. It opens to form a sphere shape.
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DESIGN PROPOSAL V.2
TOP At the end we decided to use the first design as our design for higher sense of security. It was then combined with the folding pattern. For the back part reverse fold was used.
FRONT
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SIDE
PERSPECTIVE
While developing our ideas and making the prototype, we found the shape of the patterns were a bit point toward the human body. We agree that these sharp edges might cause discomfort. As a result small squares are added into the pattern to make the points outward. Openings are also created on the upper part for ventilation and light. The back side of our design is also changed. At first, the part was attached to front using folds and it was all made out of one single paper. Considering the neck movement of different users we make the back part separately and attached it with a bolt. This allow users to adjust the back part easily.
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PROTOTYPE V.1
This is our first complete prototype in 1:3 scale. It can compress into a thin stick when not in use. We tried to capture all the essential details and movement to provide a better understanding of design ides. This prototype is made by normal white paper and for the actual design we decide to use cloudy white polypropylene for a blurry effect and better strength.
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TESTING EFFECTS
The first one shows how light gets in the prototype. The second one shows polypropylene is strong enough to hold the shape alone. The cloudy white polypropylene is semi translucent which softens the light and make the view blurry.
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M3 FABRICATION 26
FABRICATION INTRODUCTION
Since our prototype v.1 is 1:2.5 scale so a 1:1 scale prototype should be made in order to fit ourselves into the sleeping pod for more development details. The clip is another aspect that we need to discover in the following steps as MSD chairs’ back are curved and thicker than the normal chair. Bolt design needs to be further developed due to the size change of sleeping pod. For the choice of material we decide to use polypropylene and the quality of the previous prototype is not consistent because it is cut by hand. New method needs to be developed in order to cut a large amount of polypropylene quickly with consistency.
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DEISGN DEVELOPMETN - PROTOTYPE V.2 From the M2 feedback we decided to make a 1:1 scale prototype to understand the actual size of the sleeping pod and test the space inside. Paper is used for the 1:1 prototype instead of polypropylene to reduce the production time . We tried it on our body and realized the space inside was enough. However the stings really hurt so we definitely need to fold the stings outward.
We also worked on the back support to improve our design. We tried to figure out the exact pattern in real scale which will make the design as stable as possible. When we were making the paper prototype, we found that it was comfortable to leave the ends straight without the curve one so we eliminated the curves at the ends that we made in the prototype from M2.
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On the right hand side is the final pattern of the back part. Comparing to the photo on the left you can see different folding technique is used for the back part design. Reverse fold gives support to the neck without creating pointy edge.
This prototype is made out of brown paper which is slightly thicker than the white paper we used before but still it cannot hold its shape easily. However it allows the pattern expand and compress more than polypropylene. We decide not to compress the end part of the pod so that it can sit on user’s legs. As we did not have enough time so we did not fold the small square inside each square. On the right hand side is the view of the sleeping pod from inside.
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DEISGN DEVELOPMETN - BOLT N CLAMP The metal bolt we were using was too small in size and it was a bit heavy. We were looking for a bigger and lightweight bolt. We tried to 3D print the bolt in bigger size. However we could not change a lot of the dimensions as it was proportionally designed. If we did changed, the bolt would not function as a screwed bolt. We did not want to make it any thicker. Also, it was costly so we tried to find another solution.
We found this plastic bolt on the left hand side which looked like a metal bolt. It was long but we found it too thin to use and to control all the polypropylene sheets. Then, we kept searching until we found this wooden bolt which is quite strong. The dimensions of it suited our design the most. We also liked the natural and eco-friendly texture which it had. However, we remain uncertain whether it would be long enough to compress all the sheets so we thought of using two; one at each side.
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We looked at different types of clamps and clips that could be used in our design. We looked at c clamp and the way it functioned. However, the chair was too thick so it did not fit. Even clothing clip did not work.
We found this adjustable string which could be extended or keep close. The pictures on the left hand side show the movement of the string when it is pulled. We decide to use it to control the clamp .
We then created our own clamp. It was width enough to clip on the chair however it was not strong enough and fall out easily. Therefore we developed another design.
At the end we came up with this clamp which was designed according to the MSD chair back’s shape. Stretchable invisible string was used to allow adjustment.
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DEISGN DEVELOPMETN - PROTOTYPE V.3
However, it was very hard to bend the triangular pattern and the middle squares. It is because etching only cuts all the lines on the same side and it only works well for one side folding with large distance. Branko (2003) introduces different digital fabrication methods and we decided to use laser cut to cut the pattern on polypropylene as many pieces of polypropylene are required for the final sleeping pod. There are two types of methods we can use: etched and dotted line. We tried the etched line first and it gave a clean and smooth finish.
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Some of them were about to break when we tried to force them to bend. The only way to fold the same square was to cut a small hole in the middle. As a result etched lines worked very well for the main grid of our pattern (vertical and horizontal lines) but they weren’t that efficient for the diagonal lines and small details.
DEISGN DEVELOPMETN - PROTOTYPE V.4
However, these dotted lines seem to make the edges and angles sharp which may cause uncomfortable while user is inside the sleeping pod.
Then we tried the dotted line version. It was very effective as it can compressed completely and it was easy to make the squares in the middle. Dotted line allows to fold on both sides easily while etched line cannot.
Also, the dotted lines solved the problem of ventilation and letting light in. The little opening created by the dotted lines let air and a beam of light in which acts the same as the opening we wanted to add in M2. It allows lights in more evenly and finely. No extra openings are required.
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FINAL PROTOTYPE DEVELOPMENT
ETCHED LINE Since there are both advantages and disadvantages of etched lines and dotted lines we decide to combine both technique into our final template.
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Etched line gives smooth and clean finish so we use it for both horizontal and vertical lines of the big grid. Dotted line allows better folding but creates small holes at the same time so we decide to for the diagonal lines and small squares.
DOTTED LINE This allow the polypropylene folds better with smooth finish. The laser cut template is on the top.
CONNECTION
We first tried riveting and we connected the A1 sheets to create one big piece. This method did not work that well with our material as it was one plane movable and also we could only rivet the side of the sheets and not the middle part. This would not be enough to make the structure stable enough to function as one.
Then, we tried to use UHU glue but it did not also give the desired result. It did stick but seemed to weak and it would break by compressing and expanding our design. It would not stand and support that much movement of our foldable sleeping pod. Also, it looked a bit unappealing with this effect from the glue.
We also tried sewing. We first made small holes with pins and then connected two little pieces by the thread and it actually worked. It made the structure very strong and firm. Also, it would allow a bit of movement but not to the point that it would break. While black string looks quite obvious and we decide to use invisible string instead.
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OPTIMISATION The material choice creates a blurry view which keeps the personal space protected but not making the person feels completely isolated. The sense of security is provided.
Photo on the right is when the polypropylene is put in front of the light box. The light becomes softer and everything becomes blurry. In MSD the lightnings are usually stronger for people to work. Therefore this effect can help to soften the lights and encourages user to sleep. Also, using the dotted lines cut lefts an aesthetic effect and gives the design more form.
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The volume/ shape of the sleeping pod creates a suitable distance space as we often prefer to have more distance from the front rather the back. Also, on the sides still keeps space to prevent making the person feel uncomfortable or being watched. In order to have appropriate expansion and personal space inside we design to have 200 x 200 mm per square with 9 squares width and 10 squares long. The diagram on the right shows the unfold version of the sleeping pod.
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FINAL DIGITAL MODEL PLAN
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FRONT PATTERN
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SIDE
PERSPECTIVE
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SIDE
PERSPECTIVE
First of all we made one single square of the pattern out in Rhino and tried to apply it onto the body mesh. We tried different ways to apply the pattern on to the shape of the pod using panelling tools but the outcomes were not in correct arrangement and scale. At the end we decide to have both the sleeping pod on body mesh and also a flattened version of the correct 3D pattern to give a full understanding of the design. The zigzag pattern is for the back part while the one below is the body part.
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FABRICATION SEQUENCE
This is a summary of the model making process. We received the A1 sheets of plastics from the Fablab with the patterns applied on them (etched and cut). We started folding them to take the shape then unfolded them so that we can connect all the pieces together. Pin is used to make holes on the connection part before sewing. It also helps to hold the sheets together while sewing. We sewed them together using fishing thread (invisible) but kept the front part and the back part separated. Holes for bolt connection is cut. Then, we folded them again and tried to compress them using rubber bangs and belts. After that we added the connections (bolt,clamp). Small holes are made on the sides on the sleeping pod to connect the clip using adjustable string. The entire model is polished using sandpaper to reduce any sharp edges and make it smooth. At the end we curved the corner at the back because they were much sharper then the corner in the paper prototype.
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ASSEMBLY DRAWING
This is the exploded drawing for the whole model. The sleeping pod consists of two parts including the front (cover) and the back. 12 sheets of polypropylene are used, 8 for cover and 4 for back. Each piece is connected by a bit of overlapping that is being sewed. For the front cover there are 10 x 9 squares with square size 200 x 200 mm. Two different patterns are applied to the back and cover.
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This is the detailed exploded drawing showing the connection part of the back and cover. It is connected by two bolts and two stops. We first cut holes on the connection part of both back and cover. Then we used the bolt to connect both parts and held it with a stop. If more light is required one more stop can be added to create a hole.
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FINAL SLEEPING POD
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A lot of work has been done in this module. First of all the application of digital fabrication methods especially laser cut helped us a lot in producing such a large amount of pattern on polypropylenes in a short period of time. At first I tried to cut the polypropylene by hand and the lines were not straight enough and without any consistency. The used of etched line and dotted line solves the folding problems and we do not need to include extra openings for our final design. Drawing the template in computer ensures accurate angel and measurement, which saved us a lot of time for drawing the pattern multiple times. However there were many other laser cut submission and we needed to submit our template as soon as possible to make sure it was done in desired range of days. Also it helped us to calculate the exact amount of material required for the sleeping pod easily by applying the pattern to the size of a piece of polypropylene in the computer. We also tried 3D printing and the product was in good quality but a little bit pricey. Therefore we gave up using 3D printing for the bolt and search for other alternatives instead. We choose this cloudy white polypropylene due to its blurry effect which creates a suitable environment for sleeping. We are happy with the choice of material and the effect it gives at the end in the completed sleeping pod. I have learnt that there are always unexpected problems appeared in the making process and we need to prepare enough time in order to solve them accordingly.
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M4 REFLECTION
I think DDF is a very challenging and interesting subject. It is challenging because we always need do the best of us in a short period of time. As a result I have learnt to be productive and how to manage my time properly. For example I need to submit the laser cut template a few days before model-making day as there maybe be a long queue or any technical issues may appear. Lost of materials and the fablab laser cut them wrongly had happened to us before. Therefore I have learnt that extra time should be prepared for any changes. DDF is also interesting because it helps to stimulate your creativity. There are always many unexpected problems occur and I need to keep searching for suitable solutions. Problem solving is another skill that I have learnt. I have also tried some digital fabrication methods like laser cut and 3D printing. This can help me to made model easier in the future.
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By working with my partner I have learnt the importance of conversation and division of work. We both have different strength and weakness and therefore appropriate work division can bring the best of us for the project. Marian has better English than me and therefore she mainly wrote the text in the journal. For me I think I am better at layout so I did the final layout touch up when there is time. For model making it is impossible for one person to finish the whole sleeping pod in that short period of time and therefore we spent a lot of time to met up and made the model. I like to start working quite early before the deadline and I am very thankful that she is willing to response to my request. Overall I think we have a good teamwork and we are happy with our outcome.
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In response to Philip and Peggy (2008) ‘s notion of craft I think our working process fits the relationship between human and technology. More than sketches and diagrams we also use Rhino to see how the sleeping pod sits on the user in real scale. Digital fabrication like laser cut and 3D printing are also used in order to produce desired pattern and bolt. I think we also included a degree of design risk in our design. We did not know the final form of our model until we made it out at the end because the model could not be created correctly in Rhino. There were a lot of unexpected details that need to be fixed at each stage in order to come up with this final form. I am satisfied with our sleeping pod but there is still room for improvement. First of all is the weight problem. This may due to the thickness of polypropylene we chose. Maybe thinner polypropylene can reduce the weight. Secondary is the clip. We tried many methods to design a clip that could fit the MSD chair but the outcomes were not that efficient. In the final photo shooting I did not use the clip because I realized the sleeping pod could stand still only base on the user’s leg and the back of chair.
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MARIAN FAHIM MARIAN FAHIM
BIBLIOGRAPHY Branko Kolarevic, 2003, Architecture in the Digital Age - Design and Manufacturing, Spon Press, London. Enric Miralles,Carme Pinos, 1988/1991, How to lay out a croissant, El Croquis GAIA, 2009, VEASYBLE, viewed 3rd June, 2016, <http://www.veasyble. com/> Heath, A., Heath, D., & Jensen, A, 2000, 300 years of industrial design : function, form, technique, Watson-Guptill, New York. Philip Bernstein, Peggy Deamer, 2008, Building the Future: Recasting Labor in Architecture, Princeton Architectural Press. Sommer, R., 1969, Personal space : the behavioral basis of design, Prentice-Hall, Englewood Cliffs.
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