M4 Journal DDF

DIGITAL DESIGN + FABRICATION SM1, 2016 THE SLEEPING POD

PHAM Hoang Phuong Trinh 784173 Joshua Russo- Tutorial 7

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CONTENT 0.0 INTRODUCTION 1.0 IDEATION

1.1

Object Measurement 1.2 System Analysis

1.3 Reconfiguration

1.4 Outcome and Reflection

2.0 DESIGN

2.1

Design Development Introduction

2.2 Digitalization + Design Proposal V.1

2.3 Digitalization + Design Proposal V.2 2.4 Design Proposal V.3 2.3 Precedent Research 2.4 Design Proposal V.4 2.5 Design Proposal V.5

2.5 Prototype V.1 and Testing Effects

3.0 FABRICATION

3.1

Fabrication Introduction

3.2 Design development and Fabrication of Prototype V.2

3.3 Design development and Fabrication of Prototype V.3

3.4 Final Prototype Development and Optimization 3.5 Final Digital Model 3.6 Fabrication Sequence 3.7 Assembly Drawing 3.8 Complete Sleeping Pod

4.0 REFLECTION 5.0 APPENDIX 5

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DESIGN OBJECTIVE Design a sleeping pod for one person at university campus to provide user comfortable power nap without interference from surrounding environments

DESIGN BRIEF

A three-dimensional wearable second skin that responses to the concept of personal space and its boundary with the environment.

0.0 INTRODUCTION

KEY CONCEPTS

Volume Material system Personal Space Spatial and Emotional Effects Rhino 3D modelling

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1.0 IDEATION

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1.1 OBJECT MEASUREMENT

TOP VIEW

RIGHT VIEW

TOP VIEW

ISOMETRIC VIEW

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LEFT VIEW

RIGHT VIEW

LEFT VIEW

The stool was physically measured by using scale rule and protractor. The top and two sides of the stool are traced on paper to draw the basic outline following the drawing of the croissants from Miralles & Pinos(1994).

These measurements later are used to model the stool in Rhino by using InterpCrv, PlanarCrv, ExtrudeCrv command. Some parts such as side panels are mirrored by using Mirror command to boost the process. The plastic joints are modeled separately before being placed in the panels.

1.2 SYSTEM ANALYSIS

The convex surface on one panel fits perfectly with the concave surface on the other panel

The most interesting mechanism of the stool is its folding transformation , which is based on the simultaneous horizontal and vertical movements of all 8 panels.

Semi-circular plastic joint create a flexible pin joints that allow rotational movement between panels

When a vertical force (Fv) or horizontal force (Fh) is applied onto the stool, panels 1 move horizontally in opposite directions, followed by the rotational movements of other panels.

The stool gradually transforms into its open condition with the side panels forming a strong scaffold that supports the surface above.

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1.3 Reconfiguration

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SIDE VIEW

TOP VIEW

SIDE VIEW

TOP VIEW

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FRONT VIEW MAJOR DEVELOPMENT STAGES: 1. The shape is created from applying the folding principles between panels of the stool.

2. Length is added to increase the internal space and volume. Current shape appears to be quite dense 3. Holes are added to reduce density of the shape

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INSPIRATION: My sketch model is primarily inspired by the image of butterfly’s wings. These wings are flat and twodimensional but under different sources of light, it can create beautiful three-dimensional effects and the effects would change in different viewports and environment.

With its flexibility in shape, the sketch model has the potential to be developed into various dynamic structure by combining them together in many different orientations.

1.4 SKETCH DESIGN

DESIGN 1 This design aims at creating protection around the right arm and chest area which is usually vulnerable to external attack

DESIGN 2 Butterfly shapes in different scale combined together create an extended structure that provide protective shield around sensitive neck area and back, allowing user to lean on and have comfortable sleep.

DESIGN 3 Spiky chain of butterfly shapes wrapping around user’s head and upper shoulder to prevent attack and minimize interference from surrounding environment to the eyes, enabling a quality sleep

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Reflection from Module 1 The sketch model has great potential to develop into more dynamic and complex shapes.

However, the three sketch designs appear to look similar to each other and do not have much distinctive features that create complexity and sophistication.

Also, folding mechanism needs to be analyzed and utilized more efficiently in the butterfly shapes as well as how they would be joined together.

Different materials will further be tested to find the most suitable material for the structure as paper tends to dangle under self-weight, which is aesthetically unacceptable and hinders further development.

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2.0 DESIGN

Trinh Pham Henrik Green Nik Lee 17

2.1 Desgin Development Intro Considering feedback from Module 1, we decided to further develop the butterfly shapes from Trinh and the leaf shape from Nik. Our initial design is a double-layer structure, in which the interior layer provides comfort for users while the exterior layer acts as a protection, preventing interference from surrounding environment.

Module 1 Sketch Model

With its sharp and angled geometry, the butterfly shapes are suitable to form the exterior layer. Besides, the profiling surface of the leaf shapes provides perfect comfort for user.

We also worked on new sketch model to refine the current sketch model from M1.

Protective exterior layer

Considering personal space, this sketch model appears to have much interior space and is vulnerable to external interference Refined Sketch Model 1

Interior Fabric layer

Interior

Refine Sketch Model 1 solves problems of privacy by adding surface, but later its density was not suitable for our design

Plastic layer Refined Sketch Model 2

Module 1 model was cut in halves and combined horizontally.

However, this new sketch model limits the joining flexibility. In the end, we decided to revisited and further developed M1 model.

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2.1 Desgin Development Intro

Family, close friends

Acquaintances

Strangers

As the base for our design process, model’s personal space was measured by having one person changing distance from far to closer until she feels uncomfortable and each standing distance was recorded. It is noted that the model is highly sensitive around neck, chest and upper arms area.

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2.2 Digitalization & Design Proposal V.1

TOP VIEW

SIDE VIEW

FRONT VIEW

ISOMETRIC VIEW

Taking the idea of flowers and bird nest, the structure considers the visual elements of a butterfly and leafs as a personal sleeping pod.

Space gap allows peaking space

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The space gap between each panel also provides a peaking space for user, also allows light to come through, allowing a sufficient amount of interaction with the surrounding world before sleeping

2.3 Digitalization & Design Proposal V.2

ISOMETRIC VIEW

Flat sheet with wave form

SIDE VIEW

Thin strips cut from the sheet

TOP VIEW

The strips then arranged around the pod

Right elevation sketch with ribs

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2.4 Design Proposal V.3 Fabric & Metal frame

profiling cushion allows movements of the head

Foam or Fabric

Unlike Proposal V,1, we aim at designing a sleeping pod that wraps around one’s body and can be attached to an existing chair

should be soft and flexible to support the neck

connected to hand wrist

Folding movements of the external frame

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When user is sleeping, the external frame acts as a protection from surrounding environment. The upper part is enclosed in the spherical structure.

2.5 Precedent Research Not Whole Fence by Ball-Nogues

Images from http://architizer.com/projects/not-whole-fence/

Visibility and light is controlled by altering the material density of the fence. This invites interaction with surrounding environment.

APPLIED TO DESIGN

Control of light, material density can be adjusted to achieve comfortable quality of light inside the pod

Veasyble by GAIA

California: Stage Set for John Jasperse

Images from http://www.veasyble.com/

Images from http://digit-all.net/California-Stage-Set-for-John-Jasperse

GAIA focuses on the concept of isolation and transformability by creating collapsible and portable device.

Translucent polycarbonate sheets can absorb and diffuse light, and they are connected by zip ties.

APPLIED TO DESIGN

The collapsible mechanism can be applied to our sleeping pod to enhance its portability and flexibility

APPLIED TO DESIGN

Polycarbonate sheets are potentially suitable for the panels in our design. Also, zip ties can also be solution for joining the panels together

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2.6 Design Proposal V.4

TOP VIEW

FRONT VIEW

SIDE VIEW

ISOMETRIC VIEW

From precedent research, we examined the collapsible function of GAIA’s backpack to enhance the portability of current sleeping pod design.

We also decided to use polypropylene as main material for the panels due to its translucency and flexibility.

The timber frame has been profiled to fit perfectly to user’s neck and back area , providing comfort and protection from behind.

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2.6 Design Proposal V.4 JOINTS

We tested out different joints including connecting the panels by using thread but it was too thin to resist the force.

We also tried zip ties but the ties were too big, making the system looks unaesthetic.

We finally came up with the pin joints between panels by creating holes on one panel and arrow shape on another panels. This allows panels to join together without any additional joints

PANELS

Different shapes were tested to improve the current panels

Curved system required many joints, which reduce the flexibility of the structure

This structure has too much space and gap in between, which weeken the idea of privacy

We finally revisited the original shape and decided to further develop it

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2.7 Design Proposal V.5

FRONT VIEW

ISOMETRIC VIEW

TOP VIEW

SIDE VIEW

BACK VIEW

2.7 Design Proposal V.5

Translucent polyprolylence panels limit interaction with surrounding world but still allows light go through the pod and user to observe outside activities

Fastening details have been added to hold the panels in right position when the sleeping pod is used

Sharp edges of the polypropylene act as protection and prevent interference

2.8 Prototype V.1 & Testing Effect

ISOMETRIC VIEW

SIDE VIEW

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BACK VIEW

2.8 Prototype V.1 & Testing Effect Translucent polyprolylenc panels limit the observation from outside, making the user’s face gradually disappear into the white background. MDF frame with its profiling also efficiently protect user from behind.

Side view of prototype V.1

Front view of prototype V.1 Sharp edges at connection point created by arrow-hole joints between panels clearly defines one’s personal space and acts as a warning to people who attempt to approach the sleeping pod

Folded condition of polypropylene panels

Sharp edges at connection points

REFLECTION FROM MODULE 2 Module 2 marks the innovative combination between two different material systems, which are Panel & Fold and Section & Profile. Taking ideas from precedent research , we created a foldable and portable system made out of polypropylene panels with arrow-hole joints that allow panels to be connected to each other without any additional joints. This system is sufficiently supported by 3mm MDF frame that is based on Section & Profile system to provide rigid protection and comfort.

Also, the design process is greatly aided by the use of Rhino through Paneling tools, ExtrudedCrv, PlanarCrv, etc commands. Rhino plays a key role in providing a 3-dimensional representation of our ideas and efficient platform to test new design.

MOVING FORWARD MODULE 3 Prototype V,1 has series of problems that need to be further improved in next modules: - The prototype appears to be two systems joining together rather than one performing system.

- Elastic characteristic of polypropylene make the panels dangle under self-weight and gravity force, which distorts the overall structure.

- Considerable amount of force is required to compress and keep all panels in their folded position - It is difficult to compress and keep all panels in their folded position with current fastening details

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3.0 FABRICATION

Trinh Pham Henrik Green Nik Lee 33

3.1 Fabrication Introduction Taking feedback from Module 2, there are several key concepts that need to be tested and developed: The panels appear to be flat that does not create much space and volume, thus resulting in two-dimensional appearance of the structure.

Our solution is to further develop the panels into a three-dimensional shape but keeping the overall outline as we are happy with the arrangement of all panels.

Site is taken into consideration.

We chose the long bench in the atrium in Melbourne School of Design as location for our sleeping pod.

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The initial folding function seems to hinder further design development, so elimination will be considered.

With the consideration of eliminating folding function, MDF frame will be redesigned to better support the panels and to solve the problem of having two seperate system joining together.

Frequent movements and activities including walking, eating, running are observed throughout the day.

Therefore, our aim is to create a portable and flexible sleeping pod that does not take up much space or hinder movements

3.2 Design Development & Fabrication of prototype V.2

Double layers add volume and space to the structure

Outline of personal space

Top view showing internal round layer and sharp external layer

Series of shapes were tested and new panel with greater volume was created by folding different parts of panels in opposite direction

In order to increase volume, we considered having two layers: a round internal layers to create comfort and a sharp external layer to clearly define personal space and set barriers between user and surrounding environment

Folding the panels in two different directions increases internal volume

The connection points of two panels create a sharp structure that clearly define personal space

Top view of panels

Inner layer

Having eliminated the folding function, a new frame was designed to provide lateral support to the panels. Unlike the rigid geometry of the panels, the frame was designed in free form to enhance its flexibility and interesting look.

Red area shows the space created by joining two panels together to form outer layer

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3.2 Design Development & Fabrication of Prototype V.2

FRONT VIEW

SIDE VIEW

Double panels joints on front side provide higher protection to sensitive area (chest and face).

ISOMETRIC VIEW TOP VIEW

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3.2 Design Development & Fabrication of Prototype V.2

Sleeping pod tested on site

Side view of prototype V.2

Prototype V.2 solved the problem of having two separate systems joined together by placing polypropylene panels in three rolls around the new MDF frame. With its translucency, the panels soften and blur out the frame as if it has been disappeared into background. The panels also perform as semi-invisible barrier as expected.

The outer profiling edge of the frame well fits with the bench. However, the lower part of inner edge curving inward creates discomfort to the back of user.

FRONT VIEW

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3.3 Design Development & Fabrication of Prototype V.3

BACK VIEW

SIDE VIEW

ISOMETRIC VIEW

3.3 Design Development & Fabrication of Prototype V.3

In prototype V.3, rounded edges of MDF frame has been changed to angled edges.

The lower part of the innner edge has been shortened to solve the problem of discomfort in prototype V.2 Also, the the holes in the frame have been extended to allow two panels joining simutaneously.

Extended holes for double-panel joints

Rhino model and angled frame

When tested on site, Prototype V.3 showed desired effects, particularly the blurry, fading from polypropylene panels and angled supporting frame that makes the structure now looks like one performing system.

Sleeping pod tested on site: Side view

Sleeping pod tested on site: Front view

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3.4 Final Prototype Development & Optimisation EFFECTS Curved frame was changed to angled frame to propose similar system with the panels.

However, the internal edges remains rounded to ensure enough comfort to user

The orientation of the panels in internal layer were changed while the panels in external layer were flipped to show the sharp edges

Internal layer

FABRICATION

External layer

In prototype V.2, MDF got thinner after laser cut and led to breaking of the frame at the notches.

This issue has been resolved in Prototype V.3 by making the frame wider at important notches

Prototype V.2

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Prototype V.3

Use Gumball to slight the pieces apart

Notches are created by using using

before creating the notches

Boolean2Objects

After notches created, the pieces are

The piece is placed flat by Orient3Pt

moved apart sing Gumball

3.4 Final Prototype Development & Optimisation MATERIAL USAGE

We tried spray painting the MDF frame and it looks good on surface. Yet, the smell might negatively affect user

New material - bamboo plywood has been used in replacement of MDF as its texture looks more interesting the the color fit with the translucent panels

We tried sanding the burnt edges of bamboo after laser cut but it does not look as good. We decided to leave the edge in dark color.

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3.4 Final Prototype Development & Optimisation MATERIAL USAGE

The frame and panels are placed in 600x900mm and 600x600 sheets for cutting.

They are arranged closely to each other to take up less space, thus saving cutting cose

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3.5 Final Digital Model

TOP VIEW

ISOMETRIC VIEW

FRONT VIEW

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3.6 Fabrication Sequence

Step 1: Sanding bamboo to remove brunt marks on surface

Step 2:Attach vertical and horizontal part of the back frame together

Step 2.1: Put three members of the back frame together

Step 3: Insert balsa wood into the gap between bamboo frame to fill up the gap. This gap was resulted from the inconsistency in thickness of bamboo after laser cut.

Step 4: Continue adding additional vertical elements on the sides and in front to the frame

Complete frame

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3.6 Fabrication Sequence

Step 5: Trim abundant balsa pieces off the frame for aesthetic purpose

Step 6: Fold all laser cut panels and put them in different catergories for easy assembly later

Step 7: Start placing panels for inner layer from the front left

Step 7.1: Continue arranging inner layers from front to the two side. Cut off some part of the arrows to better fit with the frame

Step 7.2: Connect second layer of panels after finishing the inner layer

Final touch to make sure all panels placed in right positions

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3.7 Assembly Drawing 1 7

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The number labels indicate the order of assembly process. Pieces with similar numbers have to be constructed and held simultaneously in order connect with the next pieces. Serious attention should be paid to the notching connections as wrong assembly order might result in breaking the notches.

Blue code indicates vertical pieces, while pink code indicates horizontal pieces Balsa wood packing might be needed at some notches to tighten the connection.

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3.7 Assembly Drawing 5

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The number labels indicate different type of panels that needs to be put in correct position.

Color code shows the order of assembly process.

Green pieces are panels in internal layer and have to be assemble first. Red to dark brown pieces are in external layer.

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3.8 Complete Sleeping Pod

SIDE VIEW

FRONT VIEW

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BACK VIEW

3.8 Complete Sleeping Pod

Connection between two panels in the outer layer create sharp points, which act as a physical protection for user and a warning to people who are approaching too close to the sleeping pod.

Translucent characteristic of the panels also create the fading effect, as if the sleeping pod is disappearing into background.

Arrow joints are not only used for connecting panels together but also for connecting panels with bamboo frame based on the same principle

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3.8 Complete Sleeping Pod

FRONT VIEW

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SIDE VIEW

BACK VIEW

SLEEPING POD ON SITE

FRONT VIEW A clear boundary set between user and surrounding environment

SIDE VIEW The sleeping pod gradually disappear into background due to the translucency of the panels

SIDE VIEW Bamboo frame rest on the bench and support the neck and body.

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3.8 Complete Sleeping Pod EFFECTS

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REFLECTION FROM MODULE 3 Module 3 has proposed one of the most interesting aspect of Design and Fabrication process, which is how digital and physical model and the fabrication techniques can have great impact on the design and sometimes change the initial ideas. From week 6 readings, Kolarevic (2003, p.35-39) introduces different fabrication techniques including two-dimensional fabrication , subtractive fabrication and formative fabrication. This has broaden our understanding of great availability of techniques and how our ideas would not be limited by the lack of technology.

One challenge was that bamboo plywood after laser cut would sometimes have its thickness altered by 0.5mm. This small change in fact had a huge impact on our frame model. The 5mm notches are no longer fit with each other, thus weakening the whole structure. We had to used balsa to solve the problem and extra care was taken.

To successful produce the final product, we have been greatly aided by the help of fabrication techniques, physical model, and 3D modelling tools such as Rhino.

In addition, reading from Iwamoto (2009) on folding aspect has also helped us better understand the folding techniques and how to develop complicated structure from simple and geometric shapes. We applied these ideas into creating 3D panels by folding them in opposite directions.

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4.0 REFLECTION

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4.0 Reflection Throughout three months of designing and fabricating a complete sleeping pod, there have been numbers of interesting concepts raised in each module and challenges that I and my team had to face in order to move forward.

Module 1 guided me through the process of closely analyzing an object and designing a refined sketch model based on the physical characteristics and mechanism of the object. I was greatly amazed by the number of rules and principles I could draw from a simple stool to develop my own models. One of the very first challenges that I faced in this module was to come up with a refined design from the object. My ideas were locked into an invisible frame as I did not have a holistic approach from different angles and scale to fully explore the potential of my sketch model. Consequently, all my sketch designs bear many similarities to each other and did not really response to the concept of personal space.

Moving to Module 2, with the sharing of different ideas and designs from teammates, we came up with more sophisticated design that well responses to the main themes in the module. Rhino 3D modelling became an incredibly helpful tool to visually represent our idea and explore other potentials of the design. However, sometimes the lack of software skills might hinder the design process and did not allow us to fully represent our ideas. I also found this module the most challenging of all three because we had been moving back and forth with our design ideas many times and were completely stuck at some points. From this I have learnt an important lesson that a design is only successful when it has been tested in reality. Also, critical feedback and peer review play an important role in developing and refining our model.

The fabrication process in Module 3 helped me explore how physical/digital model and fabrication techniques can have significant influence on design process. Laser cut enables me to explore wider range of materials such as MDF, bamboo and polypropylene and understand their behaviors. However, at times conflicts also occurred that can dramatically change our design. We initially wanted to have a foldable sleeping pod based on folding mechanism. However, after laser cut the polypropylene panels and joined them together, we realized that due to the characteristics of the material, it is difficult to compress and keep all panels in right position without considerable amount of force. Testing our ideas on physical model has helped us quickly understand the problem and come up with better solution.

Overall, we successfully produced a complete sleeping pod with through different critical process including 3D modelling, subtractive fabrication, prototype and peer-reviewed feedback. Considering the concepts of democratization of energy and technology raised in the reading of Rifkin and Macmillan (2011) and this sleeping pod design, it is noted that we are living in the era where everyone is given enough tools and technology to make their own product and become manufacturers. With the help of 3D modelling, printing and advanced fabrication techniques, we can better visualize the world and go beyond the boundaries that old worlds have set.

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5.0 Appendix Bibliography Ammar Eloueni Digit-all Studio, California: Stage Set for John Japserse, viewed 05/06/2016, < http://digit-all.net/California-Stage-Set-for-John-Jasperse> Enric, M, Carme, P 1988/1991, How to lay out a croissant, El Croquis 49/50 Enric Miralles, Carme Pinos, En Construction, pp.240-241 Iwamoto, L 2009, Digital Fabrications: Architectural and Material Techniques, Princeton Architectural Press, New York Kolarevic, B 2003, Architecture in Digital Age – Design and Manufacturing, Spon Press, London Rifkin, J 2011, The Third Industrial Revolution, Palgrave Macmillan, p.107-126.

Yatzerland Ltd 2007, Veasyble by GAIA, viewed 06/06/2016, < https://www.yatzer.com/Veasyble-by-GAIA>

IMAGES REFERENCE “California: Stage Set for John Jasperse”, viewed 05/06, < http://digit-all.net/California-Stage-Set-for-John-Jasperse> “Not Whole Fence”, viewed 05/06, < http://architizer.com/projects/not-whole-fence> “Veasyble”, viewed 05/06, < http://www.veasyble.com/>

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5.2 Credits CREDITS Page Cover 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

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