Developing Tupa: Prototyping Collection
Introduction The 2010-2011 academic year marked the beginning of an exciting relationship between UPM, Aalto University in Finland and the Kyoto Institute of Technology in Japan through a course called Mechanical Engineering 310, or ME310 for short. A Master’s level course that brings students through each step of the product development process, the ME310 experience is enriched through partnerships with world-class corporate sponsors, such as UPM. Working with UPM’s new Grada™ Plywood, our team was tasked with creating a new product using this material, targeted specifically at the packaging and casing industries. This book captures many of our key prototypes and favorite ideas from the year. This progression of work eventually culminated in the development of our final prototype, the Tupa Maternity Package, which made its global debut at Stanford University’s 2011 Design EXPE on June 2nd, 2011. As the course was split up into three periods — fall, winter and spring — this book is organized according to this same chronology. Enjoy! - The UPMxME310 Team
FALL PERIOD: OCTOBER-DECEMBER 2010
Plyphone Softwood Glowing Wood Magnet
Plyphone
As our team’s first prototype, the Plyphone helped us to understand how plywood behaves as a casing material. By testing the achievable bending radii with the plywood, that may have dictated size of product casings we could build. Via in-person interviews, with Plyphone we could also test user impressions about combining wood with other materials like metal and plastic. The plywood used we made ourselves out of three layers of 0.8mm birch veneer and common wood glue.
Softwood
What if wood were soft? By carefully slicing thin sheets of veneer and taping them to a cushioned material with double-sided tape, we actually made wood soft. Feel it, scrunch it, or squeeze it, softwood appeals to our desires for materials that are anything but hard and cold.
Glowing Wood
Featuring a dynamic Electroluminescent (EL) sheet, this concept demonstrates the brilliant effect that comes with combining wood and light together. In some places the wood is thin enough to let the light shine through, with other cut shapes made into the surface to allow full light penetration. As wood and lighting are vital components in interior design, with this execution the wood appears to be producing light independently.
Magnet
With the increased bendability of the plywood, magnets proved to be an effective way to snap-fit sections together, or make closed shapes. The Neodynium magnet used here is extremely strong and when placed underneath a layer of veneer, creates a seamless and elegant connection mechanism.
WINTER PERIOD: JANUARY-MARCH 2011
PaperBot: The Angry Frenchman Plycycle Plydimensional Without An Oven (WAO) Ply Plycar The PlyFit Process Sports Wheelchairs + the Univehicle
PaperBot: The Angry Frenchman
Our PaperBot, the Angry Frenchman, gently plays off of some quintessentially French traditions. The intent of the course’s PaperBot assignment was to encourage us to work with electronics, and to build confidence in our team to incorporate them into our future prototypes, if needed. The key action performed by the Angry Frenchman was to angrily tilt his eyebrows when his baguette was removed, charge ahead and spray silly string upon identifying a target.
Plycycle production process
1 plywood
2 heat
3 push
4 bend
5 assemble
Plycycle
Perhaps a wooden bicycle isn’t exactly something new, but this one took us about two hours to design, bend and assemble. With a plywood frame that can be bent to match any rider’s dimensions, the curved pieces also act as support and suspension for the rider. And with no formaldehyde in UPM Grada Plywood it makes for an ideal children’s toy as well. This simply but sturdily built prototype also demonstrates the plywood’s exceptional strength-to-weight ratio.
Plydimensional
We found that three-dimensional shapes (bending across or perpendicular to the grain direction) were hard to achieve with the material, so we developed Plydimensional to help overcome this hurdle. This prototype works by scoring or cutting the layers of veneer to allow them to move and bend with more freedom. Either an intact veneer layer or the glue layer helps to keep the panel from falling apart completely. With this technique we could test making enclosed shapes further.
Without An Oven (WAO) Ply
As achieving the plywood’s bending temperature outside of an oven or hot press offered many design possibilities, WAO (Without An Oven) Ply was an exciting prototype. Rows of resistance wires were strung across the top of one plywood panel and sandwiched between another panel. When an electric current was applied, the heat generated successfully brought the panel to the 130ºC bending temperature.
WAO production process
Plycar
UPM Grada Plywood boasts a compelling strength-to-weight ratio and the transportation/car industry is seeking solutions to make lighter yet stiffer constructions. As Plycar is a partial car interior made from plywood, it helps to explore the opportunities in this lucrative market while also revealing wood’s visual, tactile and retro-style appeal. However, distinct challenges to the concept lie with safety regulations and the closed nature of the car design industry.
110℃-130℃
Fitting machine
Simply Powerful
The PlyFit Process
While investigating custom-fit seating solutions for sports wheelchairs, we designed a quick and simple process for creating precisely fit custom shapes. The PlyFit process follows these steps: Step 1: insert room temperature, flat, cut plywood form into preheated oven at 130℃. Plywood should reach 130℃ after about 10-15 minutes. Step 2: carefully remove heated plywood and place onto “fitting machine”. Step 3: protecting your body from the heat, use your body as a mold and sit onto the heated plywood atop the fitting machine. Step 4: remain in place on the fitting machine for 4-5 minutes. Then, remove your custom-fit plywood seat from the fitting machine.
Sports Wheelchairs + the Univehicle
Wheelchairs, and sports wheelchairs in particular, are expensive to buy and the seats especially require precise fitting to the user. However, through the PlyFit Process developed by our team even casual athletes that are disabled can still own a high-performance, custom-fit wheelchair seat made to their dimensions easily and quickly. Only through the production efficiencies of UPM Grada Plywood can these products become more affordable and more accessible to users.
Univehicle: Developed by GK Kyoto Inc. in Japan, the Univehicle is just one example of an immediate application of the PlyFit Process in the market.
SPRING PERIOD: APRIL-JUNE 2011
Shoebox/Shoe Stand Hard + Soft
Shoebox/Shoe Stand: The Second Meaning of Packaging
In most cases a product’s packing is just a lifeless vessel that protects a product while being shipped or is used to advertise it. But can a package do more? To probe this question further we created a plywood shoebox that can also be turned into a shoe stand, quickly and easily. The more shoeboxes you buy the larger the shoe stand can become, creating a stylish yet functional piece of design for any home. Plus, by designing packaging to be more multi-functional we are saving space and eliminating waste at the same time, too.
Hard + Soft
This idea shows the potential of combining the strength and formability of UPM Grada Plywood with the flexibility and expandability that only fabric can provide. Also, fabric adds a lot of opportunity to bring more color and flair into any design. Especially for gifts, a combination of hard and soft can make traditional gift packaging even more dynamic and special for the recipient.
Developing Our Final Prototype
use curved shape for rocking
how to get stable structures
The Tupa Maternity Package
multi-functional
cylinder
As with all of our other prototypes, the development of our final Tupa prototype was a separate journey in and
long life product
of itself. These next pages demonstrate the steps we took before arriving at our final design for Tupa that
focus on the U-shape
debuted at the Stanford University Design EXPE on June 2nd, 2011.
functional study
we meet ‘house’ shape
TUPA BOX
Box
Rocking Bed
Table + Chair
Rocking Toy
Rocking
Used in our online survey, this version first began to explore a rocking motion in the crib. This was a popular feature as rocking helps to calm babies and put them to sleep.
Feeding Chair
Our first attempt at creating a feeding chair, this design brings the baby to the same level as the adults at the dining table. The large dimensions of the Maternity Package made the design feasible, but we struggled to achieve one that looked sturdy enough to get mothers comfortable with sitting their babies down.
U-shapes
This drawing began to introduce the u-shape (floating shapes on top) that sits into a large, single shaped lower body. This design was also unique in that it is expandable, where the slots in the bottom section allowing the box to expand and retract to serve in different functions.
Rounded Design
The most rounded of our concepts, this cylinder shape is approachable in its design, and functional in that it creates several stools or tabletops for use in different situations. We did not pursue this design long enough to solve its possible fondness to roll away, however.
Multi-functionality
At this stage we really felt comfortable with the level of multi-functionality we were delivering. This concept clearly acted as a box for storage, but also came apart to act as stepping stool and chairs — functions that are present in Tupa today.
Five Pieces
Made up of just five core pieces, this design shows a more simplistic and elegant take on the u-shape idea.
Adjustability
A departure from our simplistic tendencies, the high number of slits and cuts made this look too complicated to use, and would certainly have been too challenging to fabricate. However it showed promise in its adjustability.
The House Box
Already showing obvious signs of Tupa, this prototype we finally named, and we named it the “house box� as it looks so much like a house or barn. It consists of a large top cover that overlaps a bottom cover, and also introduces additional coloring on the end cap pieces.
Finally: Tupa Is Here!
Tupa, meaning “great room” in Finnish, is the revolutionary new design for the Maternity Package made from UPM Grada Plywood. In Finland every expectant mother receives a Maternity Package that contains many of the essentials for a baby’s first year of life. Even the box is often used as a first bed. More multi-functional, stronger and more stylish than the original, Tupa adds the functionality of a rocking crib, table and chairs and even a toy box. Tupa is truly life’s most precious package.
Thank You!
Haruna Kawashima Heikki Soininen Julia Pettersson Hakava Kento Misawa Mamiko Nagao Paul Warrunthorn Kittiwongsunthorn Rumi Yoshida Tuomas Sahramaa