Digital Design and Fabrication M4 Journal By Liangz Zhao

DIGITAL DESIGN + FABRICATION SM1, 2017 Veillance Liangzi Zhao

(721225) Siavish Malek + Group G

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Contents 0.0 Introduction 1.0 Ideation 1.1 Object 1.2 Object + System Analysis 1.3 Volume 1.4 Sketch design proposal 1.5 Reflection 2.0 Design 2.1 Design development intro 2.2 Digitization + Design proposal v.1 2.3 Precedent research 2.4 Design proposal v.2 2.5 Prototype v.1 + Testing Effects 2.6 Reflection 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

Fabrication Fabrication intro Design development & Fabrication of prototype v.2 Design development & Fabrication of prototype v.3 Final Prototype development + optimisation Final Digital Model Fabrication sequence Assembly drawing Reflection Complete 2nd skin

4.0 Refection 5.0 Appendix 5.1 Credit 5.2 Bibliography

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0.0 INTRODUCTION Through the 'Veilliance', we endeavored to build a personal space that protects wearers from psychological invasion via blocking eye contact, as eye contact has capacity to express diverse emotion and information including amity and hostility.

The project is based on skin and bone system.

Variation of vision capacity is flexible, wearers could adjust level of its expanse.

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2.0 IDEATION

Through this module, I basically understand how does skin and bone work and the relationship between them. Additionally, details of umbrella are explored generally, and have the first on digital design - Rhino Model making.

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1.1 Object - Measured drawing

Measurement method A ruler is used to measure all length and a protractor is used to measure angles between each member.

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Mechanical Detail Scale 1:1

This umbrella consists of a octagon surface- The skin. A series of stretcher and a shaft support the surface. When the runner is in the down position, the stretchers are completely flattened along the pole. On the opposite, when the runner is raised, the rods are stretched in a circle around the pole under the canopy.

Bottopm View Scale 1:1

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1.2 Object + System Analysis

This umbrella mainly consists of a handle, a runner and many springs ribs and stretchers. Those ribs connect each other by pin joint, so that they could rotate to open and shut.

Umbrella usually used as shelter from rain, wind and sun. But, it also provide privacy for the holder, which is one of the reason why I like it.

This umbrella is black and simple. It is a ‘skin and bone’ object, bone refers to the aluminium skeleton structure and skin is black surface which is make of polyester (or nylon). The umbrella is mainly functioned through its ‘skin’ rather than bone, but they are supposed to work collectively.

What I like about this umbrella is it is quite compact when it is shut. However, it is also fragile especially at rib end, so it may be easily damaged in a windy day.

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Digital Model

ELEVATION

For making digital model in Rhino, basically loft, array along the curve are main command to create the figure of the umbrella. Skin of umbrella was created by the command of loft.

PERSPECTIVE

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1.3 Volume - Sketch Model

I engaged to use this model demonstrates the realationship between skin and bone. The skin material I use is polyster and I took out part of umbrella for bone. Pin joint is applied and that makes the strcuture flexiblelly expand and fold.

Skin withe tension try to hold two bone parts together. I found this model very interesting, and it got huge potential to form a fancy structure by creating repetitive duplicates.

Through making the sketch model, I realized the theme of skin and bone system is they work together. Bone support skin to form a surface while skin relate skin to be a strong structure.

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1.4 Sketch Design Proposal

Lantern

Cacti/Wings

Lotus

People who is friendly and extroverted usually has more flexible personal space, they tend to shrink personal space when they meet other people or stay in public. The design was inspired by latern, which can be closed inwards. Thus, as a second skin, it change along with wearer’s demand instead of rigid form.

Under the stress or during the period of anxiety, people may turn to aggressive and hostile. So their personal space shown is irregular around neck and lower part of the body. It is bound at back and it expand to sides of body when it operate.

For this ides, I attempt to mimic the organic movement of mimosa, which I hope it move organically rather than mechanically. This kind of personal space is taken place the situation of sitting. People more likely to sit on a lotus leaf, which is quite religious. In Buddhism, lotus is pure and clean, so in terms of second skin, it demonstrate tolerance.

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1.5 REFLECTION First phrase of Module 1 is analyzing an object with shin and bone system via drawing, measuring and modelling it. Heath and Jeasen(2000) demonstrated in their book, observation of an object is a crucial part of creation and measured drawing is a smart way to achieve a good observation.

Observation and anlysis of umbrella inspired me to be aware of skin and bone exist widely in our daily life. Before analyzing the umbrella I haven't consider about structure inside those objects including umbrella. However, I gradually realized a large majority of objects in out daily life are based on those skin and bone, panel and fold, etc.

At the beginning of this module I'm not sure about what 'skin and bone' is actually.

The confusion bothered me and it effects my sketch model and design, which makes my concept deviating from the fundamental concept of skin and bone - the tension.

But through model making, I gradually found the fundamental theory of skin and bone system. Moreover, skin and bone system has huge potential to create flexible and dynamic form and it is more expressive.

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2.0 DESIGN

Group G Christopher Kudlicki 299481 Huey Jean Tan 797229 Liangzi Zhao 721225

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2.1 Design development intro As umbrella we analyzed in Module 1 is a form of deployable structure, so we commenced to develop more sophisticated mechanism in Model 2. Chuck Hoberman's research on deployable structure guides us to develop deployable structure of more complex and organic geometries.

Additionally, we thoroughly defined personal space from following points.

Personal space is a representation of self and other dialect. People desire privacy in some occsions and the second skin acts as protector to some extent.

Personal space is not static, it changes with occasions and surrounding people.

Skin and bone system facilitate a 'change of state', which indicates that skin and bone system should be able to change its form and size.

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2.2 Digitization + Design Proposal v.1 Our first design is a dynamic surface based on tesselated deployable ‘stars’. The surface can be modulated by the user to provide variations in transparency/opacity and form. It defines the intimate space around the body, and expanded to eye level , which effectively control eye contact with others.

What we like about this design is it had alot of potential to creat a faboulous visual effect because of its irregualr but organised array.

Meanwhile, it lacks akin element to collaborate with bone.

Plan

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Front Elevation

Isometric View

Sketch Model 'Star' operates in changing status

Bubble Dress by Lucy Mcrae

During designing the proposal we got idea inspired by Lucy Mcrae, a body architect who explores relationship between human body and technology. We are fascinated by this bubble dress, not only because of the dazzling vision effect, but also the lightweight ‘skin’ attached the 'bone'. We considered how we could replace its structure by our starry surface and allows it to move.

Starry Surface

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2.3 Precedents Research Zumthor’s pine scaffolding supports a suspended silk cocoon.

What differentiate between usual skin and bone system and this one is its skin is placed outside. The material selection of skin is silk, they are suspended and pinned. Pine scaffolding supports outside. Minimal surface created by suspending silk, which form a cocoon.

Zumthor and Bourgeois's design inspired us to consider both exoskeleton and usual system. In addition creating minimal surface make the strcuture functioning with better visual effect.-

Steilneset Memorial by Peter Zumthor and

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Deployable structure is a great invention in field of engineering but fuses in art and architecture. Chuck Hoberman is famous for this structure, he demonstrates how objects can be foldable, retractable, or shape-shifting.

Therefore we reckon utilize deployable structure as bone system make the movement more interesting.

An operated deployable consists of repetitive scissor element (refer to figure 1). The movement of scissors permits whole structure to expand and contract as series of scissors work together, one of them move effects other move at the same time.

Figure 1. scissors in a deplyable structure

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2.4 Design Proposal v.2

As we found people tend to huddle up whne they have negative emotion, whick including arms acroos the body. The gesture indicate that part of body demands more protection, due to in psychology huddle up gives sense of safety and in biology heart need more protction, which is also human's instinct.

Thus We create two parts in this proposal, one goes around head and one encapsulate the partial body. We endeavoured to control the extent of gaze and provide more space for partial body where wearer supposed to protect.

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Our second design developed from the previous proposal, the star formed structure. We construct two identical structure and longitudinally position them.

A series of props are added for support. It starts from wearer's back and extend to visual area.

Plan

Left side elevation

Axonometric View Front elevation

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2.5 Prototype and Effect Testing

Visual effect we desire to witness is deployable structure activating smoothly, effectively control eye contact and acts as a border control, so that it can be wearer's second skin. Our prototype basically satisfy above expectations. It operates in two dimension and manually controlled.

The material selection is multiple, we intend to test both qualities and visual effect. In terms of transparency and elasticity we prefer elasticated open weave fabric, which also gives a minimal surface.

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2.6 REFELCTION

Initially, prior to deciding to focus on eye contact, we are stuck in definition of personal space. We consider it as a complex and abstract thing, such as protecting different part of body in different occasion with various people surrounded. We commenced to set some restrictions for us, we got idea about eye contact finally. Eye contact is important communication between self and other, therefore regulating eye contact is a form of self-defense.

Generally, our prototype works well and it demonstrates our brief and concept well. The deployable structure allows movement which creates regular movement. This is sort of interesting visual effect. And material selection impressed us, as it generates minimal surface within frame.

However, we also face some issues that need to be dealt with at next phase. Firstly, the movement or the mechanism is two and a half dimension, not a true three dimension, which means it is predictable and not volumetric. Secondly, skin in the system doesn't work together with bone. The skin doesn't generates tension to support bone and bone also doesn't give strength to skin. Bone is self-supporting, which deviates the fundamental theme of skin and bone system.

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3.0 FABRICATION

Group G Christopher Kudlicki 299481 Huey Jean Tan 797229 Liangzi Zhao 721225

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3.1 FAbrication Intro

Before moving forward to Module 3, we revised advantages and drawbacks of prototype v.1. We suppose our following prototype incorporate following several principles.

Firstly, continuing with deployable structure and figuring out more sophisticated mechanism, which we are looking forward to see the structure functioning organically. In addition, incorporating the whole body by increasing number of ‘arms’, enlarging the personal space. Meanwhile still developing personal space based on regulating eye contact. Moreover, enriching the role of skin, making skin and bone collaborating well. Finally, equipping the whole structure with a harness that set wearers to free from holding it themselves.

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3.2 Design development & Fabrication of prototype v. 2

Our prototype 2 has been developed from 'arch' to 'dome'. There are still four arms and they are fixed at an x-shaped wood by steel brackets. Arms are positioned as angled in order to create more organic movement, which is technically supported by fabric attached. Fabric is fixed by pin slotted through holes. And we test new material this time that is more stretcher and heavier.

Fron view

Back elevation

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Testing two differenrt fabric

prototype 3

Prototype front view

Prototype top view

Prototype Back view

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3.3 Design development & Fabrication of prototype v. 3

Front elevation

Back elevation

Left Side elevation

Since the beginning of Module, we came up with an idea that arms encapsulate the majority of body from head to thigh. It increases the complexity and demands more sophisticated mechanism.

However, there are several problems push us back to focus on headpiece instead of whole body. Firstly, if the structure works around the whole body it might too large and heavy, so that probably disable the wearer to hold and walk. Secondly, we need different span go around different part of body. And we found arms would be unstable when span elongated, which means arms vibrate a lot. Meanwhile this increases the friction between each elements and especially between two endmost elements, which makes the elements easier to break. Additionally, large skin structure requires more powerful immobilization and actuation system. More arms demands to be settle on more than one pivot point. If there is not sophisticated actuator that enables arms open and close smoothly and instantaneously, the design is lubberly that is not what we expect. Finally, the design seems like deviate the concept of personal space that is reducing psychological discomfort through blocking eye contact. Thus, we decided to focus on headpiece, which enriches concept of avoiding eye contact and alleviate the problems above.

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Front elevation

Top view

Left side elevation

Rendered prototype v3 digital model

Plan Front elevation

Left Side elevation

Perspective view

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3.4 Final prototype development + optimisation

An arm consist of a series of single element with various angles(0°,90°, 135°, 140°, 145°), Due to the reason that these elements are small and easy to be replaced, we don't worry too much about the damage issue.

Meanwhile we improve the shape of the single element by rounding the corners, which better the sharp one in terms of vision effect and it also reduce the safety problems those may arise in the future.

Round edge kit

Sharp edge kit

The single element is prone to break at the connection point with bracket, due to its property if cantilever, all load will come to the front edge of arms and drag arms downwards.

Laser cut file

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Broken part

Regarding to fixings, we have tried a lot incluidng ordinary bolts and brad pin and Chicago bolt. Bolts tend to turn to loose , that requires us screwing it tight frequently.

Alsi, brad pin cause fabric sanpping.

Therefore we chose Chicago bolts as final version as it is lightweight and shows good rigidity.

MDF is material of structure members, it is lightweight and good to be laser cut.

Although we also consider about using transparent Perspex, but it has worse performance in rigidity.

Bamboo is chose for harness, as bamboo is good at plasticity, and easy to be molded.

We changed the way of fixing fabric, replacing pins by rings, which alleviates fabric snapping.

During attaching fabric to arms we found the level of tension is not what we expect. And we realized direction of fabric manipulates the tension. This means one direction of grain gives more tension than the other one, as we suppose tension operate vertically, thus we cut the fabric in a specific way.

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3.5 Final digital model

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Front elevation

Left Side elevation

Perspective view

Plan

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1. Measurement

Firstly, we measure the width of shoulders and distance between the middle of head and middle of shoulders. And curvature of shoulders and spine are measured in order to make sure the harness suits wearer and it is comfortable to wear.

2. Laser-cuttng MDF

6. Assembly

Harness installation

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Arms fixed to harness

3. Joining single e

element

3.6 Fabrication sequence 4. Harness Making

5. Fabric cuting and istallation

CNC Router helps to cut the mould we need for harness.

This step what we've done is quite simple. Generating rhino files of mould and CNC router would do rest of jobs. And we got clean and neat edges.

Bamboo was cut as strips, shoulder part of harness consists of six bamboo strips. After bamboo was sawed to strips, wood making PVA is applied to glue them together. Then bend glued strips along the mould, and clapped mould and bamboo strips together. Keeping the still for 6 hours, PVA make it strong and solid.

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3.7 Assembly Drawing

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3.8 Reflection

In module 3 we sought to advance our prototype v3, the angled one. However, there camp up some technical issues that impede us to move forward. We faced the problem to construct a more volumetric model that working in three dimension. Firstly, we engaged to incorporate three arms each side, however, when we actuating by holding the middle part, the other two arms hardly move along. Similarly, operating any arm doesn’t actuate the whole system. Meanwhile, arms are fixed at a wooden block by connecting with hinges, but hinges make the system unstable and the common circumstance we have during testing is the whole system falling down, followed by we have to hold it up through holding the arm one by one. Inevitably, single kit suffer from frication frequently, so we broke some of them, especially those which connecting hinges. Secondly, we don’t have a smart actuation strategy. So starting the operation is manually controlled, it bothers a little. Therefore the final model design we have is based on Module 2 prototype and we equipped it with a harness. There are some aspects present our effort during Module 3.We optimized material selection, fixing types and shape of single element, all of these lead us to reach best visual effect and structure stability. Constantly, we adhere to our understanding of personal space, the final model strongly demonstrates the regulation and variation of eye contact, we like it very much.

Finally, we has a very unique experience during this Module- making harness.

We explored digital technologies including CNC milling and laser cutter, they are not exactly same but equally provide neat edge cutting. After that, we spent time on hand making glue laminated harness members from sawing bamboo to clap bamboo to mould. We harvest the pleasant result from both digital technologies and traditional handcraft.

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3.9 Completed 2nd skin

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4.0 Reflection

At the very begging off the semester, Alison has emphasized the importance of setting restrictions. I didn’t get the point until our group halt to create any physical idea in Module 2. So I gradually understand why restrictions are crucial for design and fabrication. As we know, good idea never stop to come up. When we commenced to design second skin, ideas of various aspects come out of mind, however all of them are just fragments that cannot be linked as a clear clue. After several group meeting we still not settle down, we decided stop all new ideas and focus on the research about personal space. Thinking about the occasion and personal of wearer. This decision results in that we got our main theme -controlling eye contact. For me, restrictions make the processes easier due to designing without restrictions is like walking on a fork road, we might need to make decision with every step.

In Module 1, I start to build my knowledge about design of a small object. Through drawing, measuring and modelling the object, I understand the logic behind the design and fabrication of the object. We also got the opportunity to reconfigure the umbrella and make it a new one with similar working system, and I master the principles of the skin and bone which I work with all semester. Also Module 1 help me to look at this world in a different perspective. Those objects are not only provide functions for me, but also there are designing logic and fabrication rules behind them. This is what I love and appreciate.

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Fabrication stage is more challenging. Firstly, our skill of digital modelling and physical model don’t strongly support our idea. So we need to improve these to a high level. Secondly, fabrication stage is subject to many unpredictable issues. Gravity and connection cause arms unstable and sag downwards. In addition, there is not a kind of fabric maintains the quality of both good transparency and elasticity. What I enjoyed in this module is I got the opportunity to engage with both digital fabrication machine and handmade craft. I enjoyed the certainty of accuracy brought by digital technologies such as CNC cut and Laser-cutter. Besides laser cutting the main kit we need, we also CNC milling the mould we need for harness. Meanwhile I took a risk at hand making fabric which gives different level of tension if fixed at different position. This is claimed as ‘workmanship of certainty’ and ‘workmanship of risk’ in reading.

Finally, working in a team is a pleasant and challenging experience in university, especially working on digital design and fabrication this ‘brain-storm’ subject. I appreciate and feel lucky that collaborating with our teammates who possess profound knowledge in mechanism and construction.

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5.0 Appendix

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5.1 Credit

Liangzi Zhao

Christopher Kudlicki

Huey Jean Tan

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Bibliography Building the Future: Recasting Labor in Architecture/ Philip Bernstein, Peggy Deamer. Princeton Architectural Press. c2008. pp 38-42 Harvard University Graduate School of Design website, 2017, Chuck Hoberman introduction, viewed 4th June 2017,< http://www.gsd.harvard.edu/person/ chuck-hoberman/> Heath, A., Heath, D., & Jensen, A. (2000). 300 years of industrial design : function, form, technique, 1700-2000 / Adrian Heath, Ditte Heath, Aage Lund Jensen.

New York : Watson-Guptill, 2000.

Rosenfield, K 2012, Steilneset Memorial / Peter Zumthor and Louise Bourgeois, photographed by Andrew Meredith, viewed 4th June 2017, < http://www. archdaily.com/213222/steilneset-memorial-peter-zumthor-and-louise-bourgeoisphotographed-by-andrew-meredith> Sommer, R. (1969). Personal space : the behavioral basis of design / Robert Sommer. Englewood Cliffs, N.J. : Prentice-Hall, c1969.

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