M3 Fabrication

DIGITAL DESIGN + FABRICATION SM1, 2015 M3 JOURNAL - SKIN & BONE Feng Chao & Stewart Wu Hao Tian (596539 & 668986) Michelle Emma James Seminer 1

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Introduction

In the module2, we experimented the prototypes in three directions. The first is the expandable arm structure, which represents a temporary controllable personal space and can be used to defend the wearer when he/she feels offended. The second is the chest plate which consists of a bunch of small triangular structures. Strings which start from the shoulder are attached on the structures to form a radiating pattern, which symbolizes the difference of sensitivity between should and chest.

The third is rings surrounding neck, chest and hip which show special protections on the important personal space of the body. We produced a few prototypes to test different effects and found some problems and opportunities for the final stage.

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Design development Firstly, although we managed to make the expandable structure in the module2, we could hardly open it smoothly because the mechanism on the arm was not designed properly. So the first development we do in module3 is to redesign the arm structure.

Secondly, we had two plans for the body but it would be too much to incorporate both so we select the left one to develop in M3. Thirdly, we used flurescent paint in M2 to creat a glow effect but Paul suggested only highlighting the lines instead of the entire structure is better so optic fiber might be the alternation. Fourthly, the opening direction made the structure falling down so we will change the direction of expanding

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Design development + fabrication of Prototype V.2 Prototype V2: Arm Frame Supporting Mechanism

This time, we calculate the angle with much greater precision and take the body measurement into account. We also add a handle for the wearer to control structure more easily.

The prototype shows that noew we can open the pivot on arm very smoothly all thats to higher level of craftsmanship.

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Prototype V2: Front, Plan, Elevation, Isometric

Plan

Front

Isometirc

Elevation

The fame is designed to fit perfectly into the users upper arm for this improved verison of the support frame.

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Design development + fabrication of Prototype V.2 Prototype V2: Optical Fiber Effect Testing Another experiment we do is to test the effect of optic fiber. The result is awsome and much better than our expectation. Unlike LED or fluorescent paint, the glow effect of optic fiber is impressively elegant and has some dynamic beauty. It has a deeper potential to develop in the after stages.

Also, it is an interesting material to play with. For example, when you pinch the fiber, the comprssion point will have more light passing thorugh.

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Reading Response Wk 6 Architecture in the Digital Age - Design + Manufacturing/ Branko Kolarevic, Spon Press, London c2003

Briefly outline the various digital fabrication processes. Explain how you use digital fabrication in your design?

1. Generative/ additive procedure: adding material in a layer-by-layer fashion.

-STL/SLS -Robot aid assembly -CNC precast concrete -Electrolysis forming

3D Image Scanner

2. Subtractive procedure: removing specified volume of material from soilds .-CNC cutting -Laser cutting 3. Transformative procedure -CNC bending/folding -Hydro/ explosion forming -CNC roll/ draw forming -Casting -Injection form/mold One recent shift in the use of digital technology from design to fabrication is the three dimensional scanning from physical to digital. 3D scanning softwares such as 123D catch are used to capture and scan the physical body a digital model via the process of ‘point clouds’ (Kolarrevic, 2003). This points are then converted to NURBS in Rhinoceros 3D modelling software. Now the physical model can be easily converted accurately into a digital model where we can use it as a site to work for entire project. This scanning process eliminates the need for us to painstakingly draw out the NURBS of the site which they will be working on.

3D Scanned Image Provided By DDF Studios

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Reading applied to design How does the fabrication process and strategy effect your second skin project?

Addictive fabrication allow use to customise part and components which we are unable to get from the market (Kolarrevic, 2003). This includes the 3D printed optic fibre to flash light adaptor (with specified width) and the arm frame cross and ball joints. This customised connections allow us to explore the best possible solution to the design problems we face. Furthermore, as this fabrication process reduced our workload as we do not need to search the market for materials.

3 Axis ‘Up” 3D Printer Used In Printing

‘Up” 3D Printer Used In Ready To Print 3D Joints In Rhino

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Printing

Reading Response Wk 7 Digital Fabrications: architectural + material techniques/Lisa Iwamoto. New York: Princeton Architectural Press c2009

Describe one aspect of the recent shift in the use of digital technology from design to fabrication?

The digital fabrication/computerised process offers designers quick design to production process, eliminating the intermediate steps between design and final production (Iwamoto, 2009). Through the use of parametric softwares such as Rhino-plugin Grasshopper, designers are able to change the parameters of the design and hence create a series of complex and varied products easily (ABS Plastic, KAMERMAKER, Amsterdamn) (Lecture 7).

Combining this flexibility with additive fabrication technique such as 3D printing, designers are able to create complex modules which are often too expensive to create by traditional manufacturing techniques (3D Printed Canal House, DUS Architects) (Lecture 8).

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Reading applied to design Referencing from the lectures and readings, what is the implication of digital fabrication on your design ?

Digital fabrication like the subtractive fabrication process via a laser cutter enable the manufacturing of the arm and chest components for our design with ease (Kolarrevic, 2003). This immediate digital to physical model creation allow us to create a series of prototypes within a short period of time and are able to test different materials and make immediate revisions to improve the designs (Iwanmoto, 2009).

The steps taken are as follows: First we break the 3D modelled components apart and lay them on a horizontal Rhino plane.

Next we ‘Make2D’ to be sent for laser cutting. The material used is 3mm MDF boards.

The results is that we can get an entire panel of test materials within a day.

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Prototype development Diamond Panel Chest Component

For fitting the wearer’s body better as well as creating a dynamic effect we change the diamond panels bends with the contour of the wearer’s body.

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Joints & Transitions In Module2, we struggled with materials of making joints which require a high accuracy. Timber was evidenced not strong enough and difficult to reshape. So this time we replace all the joints with 3D printing materials to make sure the accuracy of expanding and collapsing angle and they look much more elegant.

Another material advantage of 3D printed joints is that they are very light and help to reduce the burden of the structure. It is no more easy to break and can be expanded much more smoothly.

We add some triangular structures which are same as the chest part on the arm. This is for making a transition between the expandable structure and the chest part, and also refining the aesthetic feeling of the simple structures on the arm.

Top: 3D printed connection joint between frame supportive structure and expandable frame

Bottom Left: Transition Panels on supportive structure

Bottom Right: 3D printed hollow joint to allow stings to pass through

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Prototype optimisation-Effects Utilisation OF Optical FIbers Considering the intrinsic toughness of optic fiber, we shift the concept of straight tension lines to dynamic curves. This change also more suit the theme of our idea of permiable, expandable, controllable personal space which should not look rigid.

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Black Matt Finsh

To create a more contrasting effect and to bring more visual shock, we paint the structures in black and will set it on a white T-shirt. The texture of the diamond panel chest piece becomes more solid and thick. This coating process also covers the burning trace due to laser cutting.

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Prototype optimisation-Fabrication Precision Craftmanship

Learning lessons from Module2, this time we make sure the expandable structure is assembled absolutely in symmetry so that the whole thing can be expanded as the plan, not like in M2 the arms were stuck by each other because of the rough fabrication

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Precision Craftmanship

The two-way joint is very important for the design because it’s function is to transfer the compression from the arm part to the torsion on the expandable structure.

In order to make sure it is firm, we have to use hot glue but we also do not want to see the glue ruins the aesthetic feeling of the design. So our solution is to make a small chamber in which we instill hot glue to consolidate the joint and seal the chamber later. In this way, the inside of the joint is very strong and no glue can be seen from the outside

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Prototype optimisation-Material Fishing Line & Connections We use fishing line to replace wool strings for supporting the structure.

Fishing line is transparent, neat, and will not be intertwined. We also optimise the knots on the end of structural arms. The left drawing shows that using the 3D printing joints with a hole in the center, we manage to make a symmetrical connection between two ends and make sure the middle structure is balanced.

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Optical Fibers

We use optic fiber to replace the fluorescent strings because: Firstly, it is difficult to paint on the surface of strings or fishing line.

Secondly, the glow effect of fluorescent paint is not strong and can be hardly observed in daytime.

And thirdly, the limited colour does not satisfy our design. Optic fiber is very desirable in our testing. Unlike LED or fluorescent paint, the glow effect of optic fiber is impressively elegant and has some dynamic beauty.

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2nd Skin final design Collapsed: Plan, Front & Elevation View

Plan

This Rhino model shows the charaterstic of our final design. Optical fibers are attached to the diamonf chest panel and the expandable arm structure. The optical fibers converge at a sigularity point at the left shoulder and are bundled to the back. A 980 Lumens torch light luminates all the fibers.

Some detials to take note: 1. Optical cables bends long the diamond chest panel, creaitng and arch.

2. Optical fibers are connect to the front end of the expandable arm strcuture, not the back, in order to create a arcing effect.

Front

Elevation

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Expanded: Plan, Front & Elevation View

Plan

Front

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Elevation

Collasped & Expanded: Isometric

Isometric Collapsed

Isometric Expanded

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Fabrication Sequence

Laser-cut the components

Assemble the individual structures

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Assemble the arm part

Get the mould from chest

Set the joint and screw eye

Set the chest part on the mould

Assemble the two-way joints

Attach optic fiber on the chest part

Seal the two-way joints

Fill the mould under T-shit

Finish the expandable structure

Set the chest part on T-shirt

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Add transition structures

Paint colour and attach optic fiber on the expandable structure

The finished expandable structure

Put the torch in the chamber

3D print a chamber to set up the torch

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Stick reflective surface in the chamber

Assembly Drawing Exploded Diagram: Collapsed Armset

A Chest Section 1 Optical Fiber On Body 2 Diamond Panels On Body

B Arm Section 1 Optical Fiber On Expansion Frame 2 Expansion Frame 3 Expansion Frame Support 4 Diamond Panels On Frame Support

C Flash Light & Optical Fiber Connection Point

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Exploded Diagram: Expanded Armset

A Chest Section 1 Optical Fiber On Body 2 Diamond Panels On Body

B Arm Section 1 Optical Fiber On Expansion Frame 2 Expansion Frame 3 Expansion Frame Support 4 Diamond Panels On Frame Support

C Flash Light & Optical Fiber Connection Point

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Assembly Drawing Exploded Diagram: MARIO & BIGMAC

MARIO

BIGMAC

A Metal screw

A 3D Printing Joint 1 Bottom Component

B The MDF chamber

2 Top Component

1 Side Components 2 Front & Back Components

B Metal Screw Eye

3 Top Cover With A Hole 4 Circular Gaskets

C 3D Printing Axis

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2nd Skin Under Light: Front Collapsed & Expanded Arm Frame

Expanded Frame

Collapsed Frame

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Under Light: Side Collapsed & Expanded Arm Frame

Expanded Frame

Collapsed Frame

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2nd Skin In Darkness: Moving The Design

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In Darkness: Diamond Panel & Arm Frame

In Darkness: View From The Side

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