DIGITAL DESIGN + FABRICATION SM1, 2016 M3 JOURNAL - YOUR PROJECT TITLE Zech Loh
728541 Michelle James Tutorial 5
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Introduction Analysing the functions and aspects that make a sleeping pod what it is, I extrapolated two elements - personal space and comfort. Utilizing the system of “Profile and Section”, coupled with inspiration from the egg cutter that introduced me to the system, I sought to utilize “Profile and Section” to create a sleeping pod that fulfils the aspects of personal space and comfort. Focusing on two popular sleeping positions of sleeping on arms and sleeping on one’s palm, I looked into the personal space requirements and comfort provided by these positions.
Two “Profile and Section” systems include the joining of two surfaces of materials at a point and the intersection of two materials.
Sleep Suit, Forest Jesse
(C) Space - DRL 10 Pavilion, Alan Dempsey + Alvin Huang
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Design development In module 1, I explored the resting on one’s palm sleeping position and made a sketch model with movable parts, inspired by the movable element in my egg cutter.
In module 2, while I continued to explore the idea of movable elements, the development of this sleeping position led to the a prototype with a static organic form that draws inspiration from contour lines. A more indepth study was also made into the shadows cast by “Profile and Section� elements.
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Based on feedback and evaluation of module 2, the static head rest was not able to cater to the varying heights at which people might choose to rest their head at, and was also unable to effectively accomodate people who chose to sleep on the left side of their face, while the dome was unable to demarcate the personal space boundary that was at the back of the user. In response to these issues, movable parts were incorporated into the design and the sleeping pod was separated into two different elements, each catering to one of the two aspects of the sleeping pod.
This developed head rest component of the sleeping pod focuses on the comfort of the user where its movable elements, based on the intersection of materials in the “Profile and Section” system, allow users to rest their head at different heights. Being separated from the dome it, it also allows users to adjust the head rest’s proximity to the body and caters to users who sleep on either side of their face.
The dome acts as a physical demarcation of the personal space of the user. With a collapsable dome, it is able to extend to the back of the user creating a more encompassing, physical boundary for the personal space of the user. It also utilizes the “Profile and Section” system of joining surfaces for the boundary and contributes to reducing light into the internal space within the dome.
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Design development + fabrication of Prototype V.2 In the process of fabricating the Prototype V.2 for the head rest, a different movable system was developed from the earlier sketched ideas.
The prototype V.2 for the dome revealed that the spacing between the joint surfaces play a huge role in the movability of the dome’s frame, while affecting the amount of shade produced into the internal space. It also had me reconsider the joints that linked the frames together.
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Head Rest Top View
Side View
Perspective
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Dome
Reading Response Wk 6 Architecture in the Digital Age - Design + Manufacturing/ Branko Kolarevic, Spon Press, London c2003
Briefly outline the various digital fabrication processes. Explain how you use digital fabrication in your design? Subtractive Fabrication A specific volume of material is removed from a solid, utilizing electro-, chemically- or mechanically-reductive (multi-axis milling) process. This milling process can be done axially, surface or volume constrained. Additive Fabrication Product is formed by adding material in a layer by layer fashion.
Plasma Arc CNC cutting steel supports
Formative Fabrication Mechanical forces, restricting forms, heat or steam are applied to a material to alter its form into the desired shape through reshaping or deformation. Two Dimensional Fabrication There are various two dimensional cutting technologies including plasma arc, laser beam and water jet. Plasma Arc - An electric arc heats up compressed gas into plasma which reverts back to gas and is used to cut into the material. Water Jets - Highly pressurized water is mixed with solid abrasive particles which cause rapid erosion that cuts into the material. Laser Cutters - High intensity beam of infrared light combined with highly pressurized gas melt or burn the material, and in so doing, “cut� the material.
Utilizing laser cutting, I was able to obtain identical and accurately cut components that was assembled to form my model. Laser cut vs Hand cut
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Reading applied to design How does the fabrication process and strategy effect your second skin project?
The fabrication process of laser cutting allowed me to achieve components that were cut highly accurately. It also caused me to constantly consider and imagine how the model would be assembled. Two constrains of the the laser cutting process was that it restricted my choice of materials and the size of the items I was able to cut out. This laser cutting process is only able to cut certain materials. A component on the dome required precisely cut strips of paper which was not possible with laser cutting as the laser would burn the paper. The other constrain was the size where I needed a frame for the dome that was larger than the 900x600mm MDF boards that were available at the MSD fab lab. With regards to the first constrain, all the strips of paper were hand cut. In response to the second constrain of size issues, I split each frame into two parts and utilized the “Profile and Section� system of intersection to connect these two parts of the frame.
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Without size restrictions (left) with laser cut size restrictions (right)
Intersecting panels connect the two components that make the frame, reinforced with glue
Reading Response Wk 7 Digital Fabrications: architectural + material techniques/Lisa Iwamoto. New York: Princeton Architectural Press c2009
Describe one aspect of the recent shift in the use of digital technology from design to fabrication? Computer-aided design and manufacturing (CAD/ CAM) is one aspect of the recent shift the use of digital technology design to fabrication. Through the use of CAD, it has allowed designers to view designs in a 3D way, from multiple points of view as compared to the traditional 2D orthographic drawings. It also encourages the energizing of design thinking and the expansion of boundaries of architectural form and construction. Apart from aiding the visualization of the designs, CAD is linked to CAM which facilitates the creation of scaled models by rapid prototyping machines. These accurate physical models from the computerized information can be made in a range of different materials.
Templates for water-jet cutting (4), testing of mock ups (5&6), water-cutting
Laser cutting template on Rhino
Laser cut MDF board produced
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Reading applied to design Referencing from the lectures and readings, what is the implication of digital fabrication on your design ?
The implication of digital fabrication of my design is that it has allowed quick and accurately fabricated components of my design. As discussed by Lisa Iwamoto, the CAD program allowed me to visualize my physical model even before it was fabricated, and forsee potential physical problems that may have been overlooked by the design process. As mentioned by Branko Kolarevic, the accurate laser cutting proved to be true as the components were identical and able to fit perfectly.
Visualized positions of head rest on Rhino
Details that allowed the MDF panels to be cut at the proper angle
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Prototype development Head Rest
After relooking at the prototype, I decided to set the perpendicular plane into the right panel. This cut into the right panel would hold the perpendicular plane in place when pressure is applied onto the head rest.
Dome
With the size considerations of the laser cutter, the frame of the dome had to be split into two and jointed together by intersecting panels when the components have been laser cut out.
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Prototype optimisation of the Head Rest Material of Panels
Base of Head Rest
Based on the prototype made in module 2, the zig-zag section of corrogated carboard proved to be less comfortable than the smooth edge produced by a laser cut MDF board. It is also not possible to laser cut corrogated cardboard as it would burn.
For the base, a threaded bolt with nuts was used. The nuts ensured that the panels were fasten in place and provided accurate spacing between panels. The nuts were also end points for the threaded bolt as two nuts screwed against each other would prevent either from screwing outwards.
Corrogated cardboard is also too flexible and fragile for the dimensions of the head rest as seen in the bending of prototype V.2
Duct tape was also considered. However, cutting 3mm strips of duct tape would be time consuming and would not hold the panels in place as well nuts on a threaded bolt.
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Prototype optimisation of the Dome
For the shell of the dome, cloth was considered but it was too flexible and would not give support to the dome. The shaped form by cloth, unless taut, would also sink inwards into the dome and into the user’s personal space. Cloth also could not be stapled and sewing the pieces of cloth together would be too time consuming. For the dome, it requires the self-weight of the frame to unfold at the angle desired. Corrogated cardboard was too light to facilitate the unfolding angle
I attempted to use tape as a hinge for the unfolding of the frames. It was successful but weak with the corrogated cardboard seen in prototype V.2. I decided to use metal hinges for the final model as the frame would be significantly heavier.
Paper, as seen in prototype V.2 proved to retain its shape as compared to the cloth that flopped around. It also gave support to the frame that was held at an angle. I also considered using strips of plastic, but in terms of weight, structure and flexibility, I decided that paper would be the best material to compliment the MDF frame of the dome.
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Sleeping Pod final design (Head Rest)
Perspective
Front Elevation
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Right Elevation
Top
Sleeping Pod final design (Dome)
Front Elevation
Perspective Back Elevation
Right Elevation
Top
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Sleeping Pod final design
Perspective
Top
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Side
Front
Back
Assembly Drawing
Head Rest
Dome
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Fabrication Sequence of Head Rest
Panels were fitted onto the threaded bolt
Panels locked in place by nuts
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Panels spaced apart by nuts
Panels spaced apart by nuts
Perpendicular plane glued onto the grooves
Fabrication Sequence of Dome
Frames joint together
Hinges attached to the frame using liquid nails and further reinforced
Shell made by stapling strips of paper
with duct tape
Shell attached to frame
Twine added to help achieve the angle desired and provide support to the hinges
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Sleeping Pod (Head Rest)
Position 1
Position 2
Position 3
Position 4
Position 5
Position 6
Closed position
Left Elevation
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Right Elevation
Sleeping Pod (Dome)
Closed position
Side
Back
Top View
Front
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Sleeping Pod before being used
Sleeping Pod in use
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Sleeping Pod in use
Sleeping Pod in use
Appendix Architecture in the Digital Age - Design + Manufacturing/ Branko Kolarevic, Spon Press, London c2003 (C) Space DRL10 Pavilion, Alan Dempsey + Alvin Huang https://static.dezeen.com/uploads/2007/11/drltencutjointsrender-1.jpg Digital Fabrications: architectural + material techniques/Lisa Iwamoto. New York: Princeton Architectural Press c2009 Sleep Suit, Forest Jesse/ Creative Agency Image creds:http://payload.cargocollective.com/1/0/17957/198768/Test_800.jpg
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