DIGITAL DESIGN + FABRICATION SM1, 2017 PROJECT 3S Yilan Zhao
(798593) Matthem Greenwood + Group 8D
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CONTENTS
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0.0 Introduction
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1.0 IDEATION
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2.0 DESIGN
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3.0 Fabrication
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4.0 Reflection
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5.0 APPENDIX
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Fig1. Moose Head model after interlocked
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0.0 Introduction In project: Second Skin, the material system we chose was PROFILE AND SECTION, started with studying 3D puzzle moose head construction. Experiencing through the deconstruction, measurement, analysis and sketch model making to understand the system and material rules. Then basing on the design critera, we considered the personal space and concepts to design our 3S project. During the design period, we experienced times of digital design (Rhino) and fabrications (LaserCut) to achieve the finished model.
Fig 2. Moose Head model sections top view
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1.0 IDEATION ABSTRACT
Formulating design ideas were through empirical research, exploring PROFILE AND SECTION system by observation and measurement of Moose Head. Research focused on the logic of organization and arrangement of material as section systems. We draw and measure the moose head model to figure out the rules of SECTION AND PROFILE and explode our design.
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Digital model of moose head
1.1 MEASUREMENT AND DRAWING
The 3D puzzle moose head after interlocked each piece became a very complex object for drawing. Therefore, I scanned its top view, right view and front view with scale ruler together to make sure the size and scale are correct. Then I put tracing paper on the top of printed out scanned image to trace the outlines. During the drawing, I took down and re-installed amount of times to study its internal structure and ensure the correct measure data. The put pieces of sections on the drawing to check right or not. After tracing on the traces. I used A3 drawing papers to trace the drawing on the traces. Then scan all drawings and put them into photoshop to remove the unclear background and brought the curves out their tones and contrasts.
PLAN
ELEVATION
hand drawing: elevation
Compared with hand drawing, 3D drawing in Rhino is much easier. Before installing it, all pieces are flatly lying on A3 size wood panels. I firstly insert images of these 2D panels images. Then draw curves along edges of each piece. Using extrude curves to solids. Finally interlocked each piece together.
ISOMETRIC
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hand drawing: plan
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hand drawing: section
1.2 SYSTEM ANALYSIS
The section and profile system can also be called waffle system as well. The most important role it plays, I suppose, is that it can break down the complex form to series sections, flat material base. This system turns a complex form object to drawable, modelable, easy construction and transport (Fairley*lecture, 2017). Moreover, this system has another feature, that it defines both structure and form. Waffle system can be called a structured system, but when each piece’s shape change and be designed the form results. And when change the direction and angle of sections it comes out a volume. From measure, drawing and analysis moose head, I realize that section and profile system is very stable because the way elements interlocking together. Each section has more than one notching and opposes to other and lock other. These systematic and huge amount elements makes possible to design self-support object.
notchings statement
interlocking process
EXPLODED DIAGRAM
interlocking process
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1.2 VOLUME: SKETCH MODEL
Sketch model chaining arm
Section and profiling get it strength from having multiple elements running through in both directions. However, the chain here I made loose the structural benefits from this material system.
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1.3 SKETCH DESIGN PROPOSAL Sketch Design #1
INFINITE PROTECTION FRONT MOVEMENT
ELEMENT VIEW
How does this respond to your personal space?
SIDE VIEW
According to the reading, persenal space refers to an invisible boundaries to protect himself. Especially, it is tolerated closer at one’s sides than front. Therefore, this sketch is formed surround shoulders to create feeling of hugging himself which refers to safety and private space for himself. The front part has two layers to produce larger
SIDE VIEW
personal space in front. Basing on personal space can be changed in different situation,the elements are curved sections interlocked together, which create infinite sence.
FRONT VIEW
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1.3 SKETCH DESIGN PROPOSAL Sketch Design #2 Perceive A spatial invasion is whether the parties involved perceive one another as persons.
ELEMENT
BACK
How does this respond to your personal space?
FRONT VIEW
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Personal space also includes the eye contact and how people feel the physical distance. The change of personal space is emotional as well. The ideation was inspired by cirrus and branch that the forms encircle the body, how plants occupy spaces. One ‘branch’ raising up to the front of right eye to stop the sight which transforms from visual to unvisual, then reduces peiceiving of spatial invasion.
1.3 SKETCH DESIGN PROPOSAL Sketch Design #3
BACK VIEW
ELEMENT
BIRD’S NEST NONVERTAL
How does this respond to your personal space?
FRONT VIEW
Persional space can also be looked as nonverbal communication to let others recieving massage of how he thinks of other. Therefore, the form occupies the space in front of mouth, about half face. The element is simple and straightly sticking out to present strongly the distance that not allow to invade.
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1.4 M1 REFLECTION
This module starts to introduce the material system by learning one simple subject, the moose head. The three hand drawings, plan, section, and elevation, help me to understand the external and internal of it and analysis how the system works. The 3D model drawing helps me to learn the digital technique and how to design in the digital program. Then according to the reading (Sommer, 1969), I start to learn what is personal space and what purpose I want to achieve during the second skin design. I admire how logic the process is because the goal is very obvious from the beginning. And
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beginning from a simple object help me easily understand the system and based on the foundation theory I can develop and explore the system and form. When I look back at this stage, I realized that in this module I did not understand the system clearly. The analysis should be much deeper and logical. Therefore, in Module 2 it would be easier and quicker to proceed. Lucid analysis and figure out how structure and load support working, will help me a lot in module 2 to think about whether the design can be possible physically.
GROUP WORK: Ho Lam LEUNG (794491) Yilan ZHAO (798593) Su GU (815638) Group 8
2.0 DESIGN ABSTRACT
In this module, I worked with Jason (Ho Lam) and Su to combine our individual idea together, build up digital model, add effects from precedents, and manufacture a large amount of testing and prototypes to test out what effect we expected.
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2.1 DESIGN DEVELOPMENT INTRO 2.1 IDEATION COMBINE Basing on what we learned from previous research and sketch design, we decided to choose my and Su’s concepts: protection and control. The form we highlighted is the feature of wrapping. On the one hand, the wrapping can clearly define personal space. On the other, it chains model to achieve to a sense of controlling and imprison herself.
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2.1 PERSONAL SPACE ANALYSIS
After intense discussion, we decided to focus on how the main sensory changed in a specific situation. What personal space is when a woman walking on a smoggy day, on a crowed street. In this condition, she is difficult to identify what’s happening to surround her. Naturally, her first action is listening. She tries to hear what’s happened to protect herself. And she is unsure about the situation, so she tries to not attack others by accident. The right part of her body has larger area of personal space because her sub consciousness intent to explore uncertainty. When her standing, the personal space are mainly on the top body, especially the prothoracic part of her. And when she walking, her personal space to herself, the shoulder parts comparably big to control herself. Based on upon narrative and analysis, the second skin needs to achieve: extra protection on the right shoulder, facial parts to decrease straight sight and isolate sunlight.
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2.2 Digitization + Design proposal v.1 1.1
right view front view left view back view perspective view top view
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1.2
right view front view left view back view top view perspective view
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1.0Modified our design from the refined sketch design development in the previous section. Taking the curvy continuous tiles as the base, the focus of this was shifted from the whole body to upper body only. 1.2 After repeated revises, a mask-structure was added into the design, to replace the chain at the hindbrain. The major reason behind is that part of model doesn’t perform a significant effects on neither physical nor psychological personal space. Furthermore, its weight
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creates a torque moment to the whole model, which may cause uncomfortable to the person. This mask is designed as the extension of the shoulder part. Because of the net shape from the section and profile system, it can effectively diffuse the reflected and refracted sunlight due to heavy smog, as well as keep away from some dirty dust in the surrounding. In emotion wise, it provides a defense of privacy and a sense of elegance for a person walking in public.
2.3 Precedent research
Not Whole Fence / LA-based Ball-nogues Studio Concept: Fence, Sturdy Veil, Varied And Partial Views, Knot Holes, Milling Patterns
In this precedent, section and profile system are applied by two layers interlocking vertically. It creates interesting changeable views. People can see through this fence when it is viewed frontally, while when viewed obliquely, things will be blocked by the large veil. However, lights can all pass through in different situation, which will produce fascinating optical illusion effect. We were inspired by how can make fascinating illusion by repetitive systematic tiles and organic curvy panels together. We realized this unique effect can only be achieved on waffle system, by its systematic structure.
Two layers that assembled by repetitive tiles can be less interesting.
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2.4 Design proposal v.2
right view front view left view back view mask detail perspective view mask plan
In this proposal we purposed to figure the concept physically. First, highlight the hearing sensory by designing an exaggerated abstract curvy shape ‘ear’ on right back. Its form is inspired by hoodie, Its form, inspired by hoodie, interlocked in sections can effectively enhance the hearing capability. The reason why we did in this way is that, hearing will become the most important sense to be taken when sight is restricted in smoggy environment.
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Second, we made a movable mask covering the right face, which changes different positions when model moves her hand to represent a different status of hearing before and after blocking sight. The mask achieved the precedent we learn previously, organic forms inside and systematic vertical sections outside interlocked together. The body part, we weaken the body structure to highlight the two sense relationships (hearing and sight). The illusion we aim to achieve was from the previous study. Two layers, one has organic form is under the systematic sections layer.
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right view front view left view back view mask detail top view
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The development of version 2 is reducing the weight of the whole structure. The ‘hoodie’ part is too heavy and weaken the concept we want to point out ‘curvy ear’. Therefore, we determined to exaggerate and abstract the shape of an ear, maintain the mask. We started to think about how possible to make mask moveable. At the beginning, we thought to make a rail or pathway supported on the body structure to move the mask. However, there is not enough space for rail. And it will influence the beauty of mask. So
we change the idea of mask for m a piece of panel to a helmet form. As sketch shows, the helmet is hanging on the hand. It covers the right eye and exposes the right ear. When head shaking, the mask going thought the ‘big ear’, the illusion comes out.
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2.5 Prototype v.1+ Testing Effects
prototype version 1
In module 2 we handmade a part of structure about the shoulder part and mask structure to test whether illusion comes out or not. And the result is there still space problem to move the mask through the body structure, and the mask can not stably stay on head.
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1. How the mask will be looked like in real when using two materials of different transparency? Result: It cannot be interlocked or hard to assembled by thin two layer. Transparent material creates interesting light reflection and shadows, but can be more dense.
1. How much it can blocked? 2. How it looks like both from inside and outside when it is transparent or not? 3. Does the transparent one give interesting light reflection? Results: the thicker sections will block more view. Transparent material creates crystal like filter viewing from inside, but outside is not impressive enough may due to the low density. The minimum width of the interlock should be about as thick as this material.
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2.6 M2 REFLECTION
During the Module 2, I learnt a lot about how to build up 3d digital design. I realize there is still a lot of skills I need to improve. When building the digital model, I realized that how fewer skills limit the result I want to attain. During the design process, testing is appropriate important. Because most CAD programs even though can visualize those surface properties, we still need to test the material physically to find the suit one. As the testing shows, this is a long way ( Scheurer& Sterling, ). After module two we still working on a large amount of 1: 1 prototype to testing materials, structures, connecting as well.
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Based on M1 sketch drawing, sketch model and M2 prototype and testing. I find the main point or the rules that flexible enough to accommodate every testing ( Scheurer& Stehling, 2011 ) we did before, of section and profile system is the way of connection. The stable and strong structure is multiple each piece interlocked in few different pieces in different directions forces. And the notches have to be accurately, or even smaller the thickness of sections depends on the material property.
GROUP WORK: Ho Lam LEUNG (794491) Yilan ZHAO (798593) Su GU (815638) Group 8
3.0 Fabrication ABSTRACT
We working on refunding design in digital models by finding out lots of problems during prototypes making, and then solved them. We unrolled our 3d digital design on the 2D template. Whole pieces were laser cut, and we installed these by hand fabrication.
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3.1 Fabrication intro
prototype v2.1 mask detail prototype model prototype v2.2
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From the feedback of module 2, we started to think about the angles, density, and gaps in the system. Module 2 used traditional waffle structure with similar and regular grids. In this module, we would develop the traditional waffle structure to more polytropic forms. And the illusion only applied on the mask is circumscribed. We started to think about how to apply illusion on the whole model. At this stage, we did research about the different type of illusions and decided one which is suit whole model. Meanwhile, the sensory of hearing still was not obvious. The further step includes, redesign ‘ear’ part, illusion applying, lots of materials testing, notching and connecting techniques testing.
3.2 Design development & Fabrication of prototype v2 About illusion, the inspiration image shows sense of flowing and light weight on the organic, curved surface. We intended to achieve this on whole parts, to reduce sense of heavy weight of this material system. We considered how the flowing going through the body elegantly. Carefully considering the angles and various of densities of both opposite directions.
Because it would be a large model from body to head, we introduce how I (our group model is me) can wear it. Two ties connected on the body part can hang on my shoulder. And measure my body do ensure the model perfectly fit on me.
Refunding the ear part was inspired by the image right side. We intended to achieve the curvy, flowing feeling, similar with body parts, to continue and unite these parts. The ‘ear’ part would be supported on the right shoulder body, following the pattern of body part structure, going up to head.
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3.2 Design development & Fabrication of prototype v2
We noticed that the illusion is caused by the systemically change the density of each vertical section and keep horizontal as simple and regular. Because the illusion becomes obvious, when one layer keeps same gaps and other changed paternally.
In this version, we built up body by the theory I mentioned before. In the digital file, when we turning the model we can clearly see the illusion. This step is more about testing the illusion theory. Therefore, the form of design version 2 was very simple. Also considering the weight of model, we cut off few parts of horizontal sections.
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PROTOTYPE
The prototype was aimed to test material. We found the polypropylene reduce the weight. However the lightweight and softness cause the notches are not stable as cardboard. The semi-transparent material results better illusion development.
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3.3 Design development & Fabrication of prototype v3
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In version 3, we planned to complete whole 1:1 scale prototype. All of them we use polypropylene, but it totally failed. The polypropylene is too soft as a structure to support itself. And the softness of polypropylene weakens the notches when they interlocked together, the pieces form were curved and transformed. Another problem is, polypropylene is easier melted by laser cut. Therefore, this material is not suitable for cutting skinny notches on it. And we chose a bad laser cutter out school.
We realized there are a large amount of pieces. We do need a nice organization of every piece before we fabricating (interlocking) by hand.
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3.4 Final Prototype development + optimisation
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3.4 Final Prototype development + optimisation 3.4.1 Crucial component and Junctions
In the process of 3.3 Design development & Fabrication of prototype v3, we realized that the polypropylene cannot be the whole structure. Because the material feature, it is too soft and wobbly to support lots of vertical sections. Moreover, the notching on it are not stable to interlock with other.
main structure: MDF HORIZOTAL - stronger support whole structure - tight notches substructure: Polypropylene sticks
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Crucial Components: ‘EAR’ MASK TOP BODY
All of these three parts were include MDF main structure and Polypropylene substructure. The illusion of top body was very successful as photo shows. But black and white polypropylene we used on mask and ear destroyed the completeness of whole second skin model.
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3.4 Final Prototype development + optimisation 3.4.2 Materials and EFFECTS
EFFECT 1: FLOWING ILLUTION by curvy semi-transparent polypropylene strips
EFFECT 3: 4 TYPE OF DIFFERENT STRIPS PATTERNS Follow the curves of the strips and interlock them in a systematic way, the illusion will be very obvious.
EFFECT 2: COLOR clear polypropylene represents the illusion better than black and white.
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3.4 Final Prototype development + optimisation 3.4.3 FABRICATION
MDF main structure pieces
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MDF laser cut template
Polypropylene strips interlocked in MDF notches
Polypropylene laser cut template
Our fabrication of model are separated into 2 main steps: laser cuts every piece, interlocking sections by hand. In 3.3 design development & fabrication of prototype version3, we did not clearly label every piece, so we have a lot of trouble to figure out which pieces should be interlocked on which notches. This
time, we clearly label every piece systematically and layout clearly on laser cut template. It saved a lot of time for us. However there still a few problems on notches, which were not accurate enough.
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When we first interlock strips, the resilience of polypropylene is too strong to keep the specific curvy shape we designed. And they cracked MDF structure. So we use warm water and circle basin to make the curves stable.
We started from the third level of MDF structure, because it is the biggest and widest piece, which can decrease hazard to minimum of cracking. Lastly, trimming the strips. Using scissor to cut the extra parts, to reduce the weight and ensure illusion nice and clean.
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3.5 Final Digital model
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3.5 Final Digital model
LEGEND FIG123.....
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Axonometric drawing
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3.6 Fabrication sequence
1. Start building model in rhino with the basic form, into our desired look, including all analysis we did previously.
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2. Contouring sketch form into section and profile system.
3. Intersecting, boolean difference to make the notch.
4. Rotating and Make it 2D to prepare laser cutting.
5. Layout each piece into laser cut 6. Send file to Fablab waiting for template. cutting.
7. Collecting and picking out pieces making notches clear enought to interlock.
8. Startting body part first, assembling MDF frame structure, using the label as reference.
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3.6 Fabrication sequence
9. Connecting assigning jobs together, carefully interlocking them
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10. Picking out polypropylene, interlocking into MDF frame structure.
11. Jason forming the spiral structure of ear with polypropylene strips, interlocking into three structural loops.
12. We three together interlocking the body polypropylene.
13. Trimming and polypropylene strips.
cleaning
14. Finished !!!
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3.7 Assembly Drawing
Axonometric drawing of 3 parts model
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polypropylene laser cut template
MDF laser cut template
digital laser cut template of whole model
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3.8 Completed 2nd Skin
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3.8 Completed 2nd Skin
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3.9 M3 REFLECTION
In this module, we were efficiently improving and develop our design idea further more. During this module’s exercise, I was more familiar with how design resulted from abstract idea to physical model even product. We firstly built up our idea to digital 3-dimensional model. It is very exiting that how the design from a point, a line to solid and organic form by my hand. This step I believe is more subjective. Because, when I was doing the digital design, most of I thought about are how to make it pretty and make sense of our concept, rather thinking about whether it is possible to build up physical model.
are not accurate enough, especially there are errors when we put on laser cut template. The laser cut method is perfect suit to our system. According to Kolarevic, that laser cut only can cut vertically and directly pieces’ edges. Undercuts cannot be milled with threeaxis milling machines (Kolarevic, 2003). In the waffle system each of pieces is quite flat, but when they combined together with the organization, the object turns to 3-dimentional with continuing form. Then we collected laser cut, picked out all pieces and interlocked them systematically.
After building up the main form, we used the command: contour, trim and etc to make sections and profile pieces. Next, we fixed During this time, I learned that a design product comes out with the details, the notches. We used commands: slip, Boolean units, heaps of times testing, changing, refunding. We had to face intersect etc to trim out the gaps. every problem happened during the model making. When we Then we made them into 2-dimensional, only keep the edges of were struggling on the notches, I was freaking out. But we finally completed all. Being patient and learning precedents are very each piece, layout them on laser cut template. In this period, the problem I found is that the shortage of digital important during design and fabrication. program skills bounded my design idea. The notches we made
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PERFORMANCE
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4.0 Reflection ABSTRACT
Critical reflection of my overall design process and experience. What have I learned, what aspect of the studio did I find challenging. How can I improve my design.
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As an architecture student, this is my first complete design. I am so glad to experience the whole design process from ideation to fabrication. One of the most themes I learned is the process of how to design whatever it is a building or product. Step 1: Define the solution and goal space. (1.0 IDEATION) Step 2: Testing against goal prototyping. (2.0 DESIGN) Step 3: Develop new solution based on previous results. (3.0 FABRICATION). Designing from ideation to physical object process is a back and forth between puzzle making and problemsolving, connecting evaluating the solution and trading off goals. These steps form the design possible, buildable and reasonable. The process was going through the whole semester. Writing this reflection, I looked back steps we did. It is so exciting that how we built up our design from learning a moose head to this complex work. To achieve it, we did so many testing and prototypes. And these steps supported us to closer result. The group work touches me how to communicate to other, how to persuade other or accept other’s ideas, how to cooperate with other and trust my group members. Because of the unity, we could complete these process. When I built up digital models, I found sometimes it was very hard to control the program to do the thing as same as my imagination. And this numeric staff made me lose the direction when I designing. The whole process shows we changed a lot of our work. Even the final model is totally different compared to the beginning of sketch ideas. One reason is we still have to improve how to use the program. The other is that the different thinking systems between computers and humankind mind. Marble (2008) mentions
that ‘ the most challenging aspects of the development of intelligent machines has been the transfer of knowledge from humans to computers.’ During building up digital model, we three tried to achieve the idea on it, however, we cannot copy exactly what we think of model. Sometimes, we even complained it waste our times. And the illusion (polypropylene strips) we couldn’t show in Rhino. Fabrication is more challenging than anticipated. From materials use to details design like notches troubled us a lot. The risk of melting material by laser cut forced us to change the design to reduce the risk. We do think about the degree of design risk in our work. We thought polypropylene is a hard control material because of the feature. And testing verified it. And the connection in this system is a big risk for us. Because it needs accurate data to ensure they can interlock and tighten each other. Moreover, the shape of each section impact how we assemble them. For instance, our body part structure, the ties using for shoulder support are arch formed. If is very risky when we put in the horizontal pieces. The top point of arch ties are weak and cracked when we interlocked sections on them. Moreover, we haven’t realized that polypropylene has such strong resilience which broke the MDF structure. Marble (2008) said craft has been mediated the relationship between human and technology. However, in our design process, craft is not only for this but played an important role to finish and complete design. The testing and prototypes help us ensure the materials and refund the form to be suited for a human body. But the final step
of interlocking strips was totally made by hand. We designed the strips form by hand drawing and then interlocking them casually.
It is worth to mention that analysis clearly the material system is very important. Section and profile system is the only system of these three can be both structure and form at the same time. However, in our design, the feature of it did not embody this. To achieve the illusion, we used clear polypropylene. However, the material cannot support as structure. So we had to separate the main structure (MDF) and substructure (polypropylene strips). I believe it can be somehow to improve the design to achieve the advantage of this system. Overall, this subject teaches me a lot, the programming skill, design theory, group work, fabrication methods, being passions and brave to solve problems.
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5.0 APPENDIX CREDITS
Yilan zhao
Su Gu Ho Lam LEUNG
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BIBLIOGRAPHY
A.Kilian (eds). (2007). Surface that can be built from paper / In H Pottmann A Asperl. M.Hofer. pp 534-561 Bernstein, P. (2008). Building the Future: Recasting Labor in Architecture, pp 38-42 Conceptmodel.tumblr.com. (2017). conceptMODEL : Photo. [online] Available at: http://conceptmodel. tumblr.com/image/138815034608 [Accessed 8 Jun. 2017]. designboom | architecture & design magazine. (2017). not whole fence by ball-nogues lines baseball field in texas. [online] Available at: http://www.designboom.com/architecture/ball-nogues-studio-notwhole-fence-11-11-2014 [Accessed 8 Jun. 2017]. Rifkin, J. (2011). The third industrial revolution. Engineering & Technology, 3(7), pp.107-126 Scheurer. F. and Stehling. H. (2011). Loast in Parameter Space? Pp70-79
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