Digital Design Fabrication | Sleeping Pod

DIGITAL DESIGN FABRICATION SM1, 2016 SLEEPING POD Team: YOUJIA HUANG CHUN TUNG TSE Tutor: JOSHUA BATTERHAM

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Module 4 Photographing Stage 3

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CONTENTS 1.0 IDEATION 1.1 Object 1.2 Object + System Analysis 1.2 Volume 1.3 Sketch design proposal 1.4 Reflection 2.0 DESIGN 2.1 Design development intro 2.2 Concept 2.3 Digitization + Design proposal v.1 2.4 Precedent research 2.5 Prototype v.1 2.6 Testing Effects 2.7 Design proposal v.2 2.8 Reflection 3.0 FABRICATION 3.1 Fabrication introf prototype v2 3.3 Design development & Fabrication of prototype v3 3.4 Final Prototype development + optimisation: 3.5 Final Digital model 3.6 Fabrication sequence 3.7 Assembly Drawing 3.8 Completed 2nd Skin 3.9 Reflection 4.0 REFLECTION 5.0 APPENDIX 5

IDEATION

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1 . 1 OBJECT The stool is photocopied in black and white to emphasis the form. Later, the photocopies are being traced over.

Dimensions are measured by ruler from the drawing as well as the object itself to have a comparison for more accurate measurements.

In rhino, use Backgroundbitmap to contend the measure drawing. Used surface from planer curve to create surface after tracing over, and extrudes surface. Fillet edge to create rounder edge. Round nodes are created by using Ellipsoid.

Array hole to form the waffle on the inside.

Stool Plan SCALE 1:3

Folded Side Elevation 8

Front Elevation

Side Elevation

Digital Model Of Stool 9

1 . 2 SYSTEM ANALYSIS

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JOINT

WAFFLE

Each panel is connected by nodes joints. Spherical nibs allows rotational movement, convexed line in the hole fixes nib in place.

It acts as reinforcement for the stool. The top panel has diagonal bracing and weight bearting side panel’s waffle is diagonal.

The stool is formed by symetrically identical panels and can be folded from flat plane to an object with greater volumn. the folding design allow the object to pack away easily and saces storage space. The Material/Plastic: Moudable when heated and hardens when cooled, high flexibility, medium to low hardness, generally will not shutter or break, waterproof, cost effective.

1 . 3 VOLUME

Panels of the stool is rearranged either in a linear or a circular way, the arrangement is amplified by repeating the same arrangement patternusing more panels and creating a set of different volumn. The making method is by oragami. using a flat sheet of paper and foldes a set of line arranged in a pattern, then forcing or pushing the paper to form different columns, that the folded line becomes the connecter between each of the “ panels�.

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1 . 3 SKETCH DESIGN PROPOSALS

CONCEPT #1 TOPED UP, PRIVATE The pod has triumpzum shaped panel that is arranged into a star circular pattern and is stacked on top of each other, and is joined to the pod beside it. As the pattern repeated forms like sea reef pattern.

The triumpisum panels can then disarranges in to different forms, that the design of the pod is flexible.

Each person has an almost enclosed sleeping area, the the space is very private which gives a greater sene of security.

When people falls asleep they are almost not cautious of what is happenign around them, the panel surrounds the body acts as a protection layer.

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CONCEPT #2 HIDDEN, SAVES SPACE, COMFORTABLE Rectangular prism is the sleeping pod, that they are arranged in a repetitive pattern. When the pod is not in use, it is like any regular floor panel. The “floor panel� can be pulled up to form a space inside for people to sleep in.

Each person has their individual pod, that the pod only has one opening, which opens at the foots, where the least individual space is needed. Each pods openign faces different side, that people does not have nap face to face to a stranger.

CONCEPT #3 TWISTED TEMPORARY Twisted rectangle shape creates a lope plane, that people can lean on it, taking a nap without completely lying down, leave and go quickly.

The space has only one opening and the upper body area is enblosed. Sleeping with stranger around may creates a sense of insecurity.

The stacked up pod only has one way access which allow the space to be personal, that the view of the user is set straight, that they can immidiately recognise of there is people comming up.

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1 . 4 REFLECTION

Measurement of the object could be more accurate, which by using flexible measuring device rather then rigid straight ruler. Flexible medium such as string, can measure the round edge more accurately, that the string is the marking device and later be measured by ruler. This way, more accurate measurement could be produced, The sketch model could been further developed by repeating the same form, which the sketch model I created was too linear and opportunities has been missed by leaving the model at the basic stage.

As for the sketch design, in term of personal space, only view of the user has been considered in to the design, that strangers’ reaction should be considered. That the design did not communicated with strangers effectively, if some defence mechanism is attached to the pod which may form protective shield to the personal space.

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DESIGN YOUJIA HUANG CHUN TUNG TSE

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2 . 1 DESIGN DEVELPMENT INTRO

Idea of exploring the folding characteristic of the folding stool remain the focal point of the design as our team is formed.

Concepts of personal space are formed by combining two element together, spikes extended from top to bottom like a sleeping bag, which the purpose is to protect user from strangers intrustion and soothes users uncomfortable feeling to others.

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2 . 2

DESIGN PROPOSAL V.1

COMFORTABLE, PERSONAL SPACE,LIGHT Sleeping pod design is a fusion of the two element, spikes and sleeping bag. There are holes at the peak of the spike to allow air to flow inside and keep body cool while sleeping, that the size of air hole gradully increases from top to bottom.

The pod is foldable, it can be stretched o reach full body size, and pack away into a more flatter volumn so it can be easily packed away.

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The pod is adjustable, with different type of folding method. It can be folded to smaller surface, opens to a greater volumn that can contains a person.

Spikes around the head space are fully enclosed, and different type of openings can be adapted as the spikes arrange down the body, since the enclosed spike becomes unecessary.

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2 . 2 DIGITIZATION

Front View

Perspective View

Back View

First Digital Model Design

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Location: ERC Level 1 Large space, spaces for sleeping pod can be made available.

Opens from 7am to 1 am, sleeping is necessary for people to study late and to allow more efficient studing quality.

Personal Space Diagram: Length of spike is to suggest personal space, which more spaces is need at a pesonal front than the back.

Personal Space Diagram

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2 . 3 PRECEDENT RESEARCH

California: Stage Set for John Jaspere, by AEDS/ Ammar Eloueini Flexible, Movement, Unfolds The zip ties connexts every pieces together allow greater flexilibility, that the object can move along with the performer. The joint system is applied to our design, which panels in our design can be joined together with zip tie or fishihg line. The loop formed by the joint system allow rotational movement, which is similar to the movement of the stool.

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2 . 4

DESIGN PROPOSAL V.2 Foldable Sleeping pod is attached to the corner between the wall and floor.

Each of the convex line is adjustable, it can either pulled out to form a space or pushed into the corner to become part of the wall and floor. User can lie on to he space to sleep. The space around the head is tow sheets of panel join instead of many lines, which allows the head to be fully covered and creates a darker and isolated space.

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2 . 5 PROTOTYPE V.1

MATERIAL: PVC foam CONECTION METHOD: Cable ties Evaluation: This prototype used different panel system, where only two panel is used to form a spike instead of four and the intension for this system is to create more rigid structure. However, the material used is too thin, and cable tie connection makes two panel are sticking together not forming cone shaped volume as desired. In addition, the piece is too heavy to wear on a

MATERIAL: Foam shield CONECTION METHOD: Fishing lines EVALUATION: Properties of material include being effective against heat, sound and absorbs vibration, which may be helpful in creating an acoustic barrier between the user and the outer space, allowing a more comfortable sleeping space.

Panels are connected by weaving fishing lines to holes and only lose weaving allow free move-

MATERIAL: Yoga mat/XPE foam CONECTION METHOD: Fishing lines EVALUATION: The material is thinner than foam shield and with greater flexibility. Fishing lines joins each panel together by tieing each hole separately. The form can be fold from a flatter plane to a greater volumn. Perfoms the function of our concept, that it is able to compress, seals agains light and soft.

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2 . 5 TESTING EFFECTS

PHOTO BELOW:The testing accentuates that the majority part of spike will deform and inner part facing the body has some rigidity, which can support the body as cushion. In addition, the spike compress into a linear plane instead of compressing perpndicular to the surface that this may creat more comfort, that perpendular compression may results in bumpyness in the back and creating discomfort.

PHOTOS ABOVE: Photos were taken from the inside in a day light environment. The effect suggests that most exposure to light can be stopeed. Some light comes from gaps between panels and holes for the joints. However, the inside light source forms an interesting pattern.

PHOTO ON THE RIGHT: Spike distances user to the extrior elements, forming personal space to the user.

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2 . 6 REFLECTION

Digital design software creates opportunities for our design, which by experimenting with paneling tool allows us to expand form of the design. However, our limited knowledge of the software also restricted us from designing our idea precisely, which exploring our idea using rhino was not stretched to full potential.

By exploring our design through “abstraction of reality� assists us to further consider on the details and function of the design, which helps to guide us to next stage, Prototyping enables us to see the suitability of various materials, and tests weather the material meets the comfort standard we are seeking.

However, by only making single element or one set of spike restricted us to understand the functionality of the entire pod, which the properties of material maybe enhanced or reduce in a larger form.

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FABRICATION YOUJIA HUANG CHUN TUNG TSE

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3 . 1

FABRICATION INTRO “Thinking and doing, design and fabrication” More prototype where created at this stage to fulfill our main concept of “comfortable”. Detailed making process need to be considered in term of making the final model, where dimensions, materials, joining methods are to be determined. Furthermore, aesthetic quality needs to be considered in order to produce a more beautiful model.

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3 . 2

DESIGN DEVELOPMENT

Exploring Variation In The Shape Of Spikes 29

3 . 2

FABRICATION OF PROTOTYPE V2

The existing or prefabricated foam pieces were indesirable in fully fulfilling the quality or aesthetic of our design. In this case, we decided to produce our own panel pieces by sandwiching foam piece with fabrics.

Fabric choice was based on comfort, which bed linen fabric type; top pop poplin is used. However, different type of poplin performes different tactility effect(right). In the end, 80% polyester 20% cotton poplin is chosen based on class preference.

In changing the material choice, connection detail is changed from zip tie to sewing. Different stitching or seam features were being explored(bottom right).

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3 . 3

DESIGN DEVELOPMENT

Side

Front

Plan

Isometric View

Developed Digital Design 31

3 . 3

FABRICATION OF PROTOTYPE V3 TESTING MATERIALITY

TESTING AESTHETIC EFFECTS POLYESTER STUFFING: very soft and comfortable in function, but stuffing resulted in uneven surface which is undesirable for our design.

PEEL FOAM: soft and mattress quality comfort. Flat and panel like appearance allows creation of favorable paneling system.

POLYESTER BATTING: very soft and it is too thin, which produced too much flexibility, and lesser cushioning.

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EYELET: a choice between metal or white paint coat finish, but decision may result with final fabric choice

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FINAL PROTOTYPE DEVELOPMENT TESTING FUNCTION Our design intention is to isolate the light from user and covering of the side square hole is necessary to achieve this concept.

Foam is removed for the square covering to prevent the inside space becoming too sealed up. Also, two layer of fabric is used to dissolve some of the light going in. In the beginning, the covering systemis 2 trangular shape forming a square and we found that the shape is not possible in covering all the holes, since not all holes are perfect square. Later the system is changed to attaching two four sided polygon, which allows movement of the hole both whem folded and stretched.

Exploration of methods to cover the rop hole such that the user’s head will be positioned at the closing of the design, which avoid the bag from falling and being too flexible.

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3 . 4

OPTIMISATION SEWING METHOD: we adapted this method in the final design, since it creates a clean look and performs the function, only careful and dense sewing is required to stretch aerthetic quality to the limits.

ZIP: Creates a bulky look and does not fits the aesthetic quailty that we are trying to achieve.

VELCRO: Chunky apperance and it’s stiffiness prevents the spikes from compressing, user will feel uncomfortable with these stiff element around them.

SNAP BUTTOM: too weak in term of strength, that it did not held the weight of one set of spike, which will be impossible to join all the spike together.

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Colour grey is choosen for our final model. Firstly, colour grey is perferable by most people and it is not a biased colour. Also in term of the colour quality of the material, that grey fabric has more even tone for different rolls compare to other vibrant colours. In addition, grey is more of a peaceful colour that soothes people allowing them to have a blank moment and quality of sleeping can be improved.

MODEL TEMPLATE OPTIMIZATION Size of each spike set were determined. Connection system for fabrication process is clarified by separating each layer to different colours 35

3 . 5

FINAL DIGITAL MODEL

Side

Top

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Front

Bottom

Isometric View Due to the nature of material and flexibilible connection details, the final model may be longer than the digital model, and the wright of the model also may extends final model’s length.

3 . 6

FABRICATION SEQUENCE

Fabric Size Actual Size Foam Size

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Plan for each panel were created, each spike is symetrical that only one side of spike plan is created and offset to fabric and foam size.

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Foam and fabric plan is arranged to A0 paper size for printing. Each panel is labeled to avoid confusion in the assemblage stage.

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Plan for fabric and foam is printed, and each is being cut out.

Fabric and foam plan is on a same sheet to reduce paper consumption.

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Fabric is cut first, that Foam pieces are cut Two pieces of fabthe plan can be and each pieces is ric with a foam are reused for foam. Printed labeled to allow more sandwiched and pinned plan each piece is orga- efficient fabrication. together in preparation nized in a way to reduce of sewing. the waste in fabric.

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Holes on the panel are produced by hammering the eyelet.

In this stage, the paper plan is being reused as a stencil for locating each hole.

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Each spike sets are Edges with loose created by using seams were trimmed sewing machine to stitch to enhance the aespanel pieces together, thetic quality and user’s precision in sewing is re- comfort. quired for a clean seam edge and be accurate.

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Each spike set are Hand held sewing connected by pinis used for stitching ning the “square hole” “square hole” and spike panels. sets together, since the model is too large to be sewed on a table sewing machine.

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Top and bottom, side spike sets’s connections are sewed with pure hand craft.

Denser stitching pattern allow rigidity in the connection as well as enhancing visual appeals.

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Complete..

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3 . 7

ASSEMBLY DRAWING

1. Single spike sets formed by joining eight different panels together.

2. Spike sets are then combined side by side in a circle as one layer.

3. Square covers are set to enclose the opening between layers.

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4. Different layers are joined together on top of another to form the spiky sleeping bag

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3 . 8

COMPLETED SLEEPING POD

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MAIN FEATURES 1. Big spiky sleeping bag to scare or overwhelm people away 2. Block or diffuse light and noise 3. Airholes and fabric square for ventilation 4. Fabric and foam sheets for providing comfort 5. Foldable for flexible usage 6. Adjustable interior space by its foldable design to suit different people 7. Adjustable closing

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3 . 9

REFLECTION By using rhino to assist our design process, productions of ideas to physical model was made more effective and efficiently. Digital fabrication saves us time from making or testing ideas repetitively. Plan were created by using rhino to allow greater precision in the fabrication process and utilized subtractive fabrication in our making process.

By making more prototypes allow us to be “thinking though making�, which making is the best way to solve problems or express ideas. For example, the flexibility in the form of hole covering was developed through testing out different shape physically, which sometimes digital model does not solve the reality problem and physical production becomes important.

Though we were given opportunities of laser cutting, peeled foam was not able to be laser cut, though laser cutting the fabric may reduce our work load, it can be unnecessary, which cutting fabric or foam piece by hand can be more effective and energy saving.

Also though the fabric may be perfectly cut, the perfect cutting edge will be hidden or be trimmed in the final look since sewing is the focal point to create a clean finish to the design.

Sewing straight seam and accurate connection of each panel is important in term of producing clean finishes. However, perfect sewing only can be developed with practice, our limited experience with sewing bound us from extending the craftsmanship of the model to its limits. Also, our limited experience result in fragileness in the final model, which seam connecting the spike set to the square hole where coming apart. In this case, testing of the craft method is important, that handheld sewing machine was misleading and the single threaded seam does not have enough strength to connect the main components of the bag together. If the connection of square panel to the spike was hand sewed the bag would be more durable.

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REFLECTION Digital design and fabrication introduces us to the fundamental of transforming ideas to physical model, making more complex system using digital software and fine craftsmanship. The course helps me to adapt designing in a different and more effective approach, develops paths of thinking to solve design problems.

Accuracy and precision is the center of digital fabrication and its challenges me to think the design greater details, which each process need to be carefully thought as it may effects the final product’s system greatly, that the final product may be broken when details are being ignored. Such that if the connection details for our sleeping design were taken to a different approach, the final pod may not fold in the way we desired. Similarly, craft in architecture is closely ties to detail. In the fabrication process, accuracy in each of the production stage is important. When one step is been less precisely performed, all the other processes followed up need to be altered and it will affect the final appearance of the design. For example, during the sewing stage of fabrication for our sleeping pod, the seam in calculation is to be 2mm off the fabric edge, however, with limited experience in sewing some pieces are sewn either too far off or too close to the edge, which later sewing with 2mm off the edge detail will be altered when connecting pieces together and changes the dimension of the of the final design.

One of the other challenge faced with our design is that consideration of the weight is been ignored, since we only produced single spike set and presumed that the final pod will be light.

The scale of our pod is overwhelming that the weight of the design becomes very great and the pod will not stand to form volume without a person holding it on the inside, the opening on the top is too large to be held by a person’s head, which the pod will naturally fall to ground.

In this case, problem of opening is solved by thinking through the different existing adjustable opening system, and we used rope and toggle to allow adjustment in the opening. However, the weight can not be changed which allows opportunity for further improvement of the system. In this case, more material testing is required to reduce the weight of the pod and comfort in the material property remains in its significance.

Ultimately, digital design and fabrication allows innovative opportunities, enhances level of accuracy.

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APPENDIX Sommer, R. 1969. Personal space : the behavioral basis of design / Robert Sommer. Englewood Cliffs, N.J. : Prentice- Hall, c1969.A Kolarevic, B 2003, Architecture in the Digital Age - Design and Manufacturing /Branko Kolarevic. Spon Press, London Marble, S, 2008. Building the Future: Recasting Labor in Architecture/ Philip Bernstein, Peggy Deamer. Princeton Architectural Press. pp 38-42

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