DIGITAL DESIGN + FABRICATION SM1, 2017 M3 FABRICATION-PANEL & FOLD Deon Cham Dao Xuan(783866) Shiyu Li (692182) Zhuo Zeng (692097) NIC DINGWEN BAO / 11
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3.1 Introduction
Submissive concept The design intent of our second skin directly conveys the feelings of the wearer without verbal expression but through rotational movement and surface enclosure (open, half-open and closed). The wearer also has control over their second skin to accommodate different type of situations and scenarios in their daily activities. We summarised these scenarios into three separated categories. Black (strangers) - total darkness, rejection, self introspection Translucent (impermanent - Intimate to Social) - wavering, uncontrollable emotions White (personal distance) - bright and visible, friendly interaction, self-confidence From the feedback of M2, there are some specific problems that need to be resolved.
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Feedback from M2 Hexagonal connections Our initial prototype was constructed with only hexagon patterns forming a spherical surface, which is relatively impossible to build due to angular errors. Dynamic structure Based on our previous design, the tutor and guest critic suggested that the overall design was too uniform and dull (spherical form and and identical hexagonal patterns). Flexibility of the materials Three different materials were used in our prototype, which are polypropylene, black board and mount board. We made use of three different materials in order to make the best selection in terms of flexibility. Black board and mount board were strong and rigid but very difficult to fold, thus indicating poor flexibility. Development of shoulder support We managed to test the mechanism of how our shoulder support should work but have not fully developed it yet. We used balsa and white paper but it was not strong enough to hold a certain amount of weight.
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3.2 Design development + fabrication of Prototype V.2
Flexibility of the materials We eventually settled with polypropylene as our material for second skin out of the three tested materials as it is more flexible and is available in many differe
Hexagonal connections By understanding the mathematical concept of polygons, we noticed that hexagon patterns must have some connections with pentagons to form an org but also formulated a more dynamic structure to add to our second skin.
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ent colours. This benefited us because our design incorporated three different colours, which are black, white and translucent.
ganised spherical surface without any overlapping. Hence, we tested our second skin with grasshopper plugins. Not only did we resolved the patterning,
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Design development + fabrication of Prototype V.2
Shoulder support Emphasising on the spiral growth of the pineapple, our shoulder support intends to make our second skin rotatable. Hence, we further developed our support’s prototype and made changes for the material. In order to implement the rotational function, we considered having a circular frame in between two bigger frame that resembled a parallel flange channel. This way, the frame will be attached to the shoulder support while being able to rotate.
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3.4 Reading Response Wk 6
Two Dimensional Fabrication The most widely used fabrication technique that involve various cutting technologies, namely laser-beam, water-jet and plasma-arc. Each technology uses different physical mechanism principle but mainly based on high pressure and intensity cutting of materials. Subtractive Fabrication This technique involves cutting or abrading excessive materials away, leaving desired forms from existing materials using electro-, chemically- or mechanicallyreductive processes. Additive Fabrication This fabrication is the process of conversing of milling to form free solid forms by adding materials in a layer-by-layer fashion, such as 3D printing and Selective Laser Sintering. Formative Fabrication The reshaping or deformation of materials such as moulding or die-casting, into preferred shape. This technique can be achieved by applying mechanical forces, restricting forms, heat or steam. For our second skin, we mainly utilised two dimensional and subtractive fabrication due to our choice of materials. By using Rhino, we arrayed our shoulder support and second skin over sheets of perspex and polypropylene respectively.
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3.5 Reading applied to design
Lasercutting our materials helped us more efficiently during our process of fabrication. For example, it sped up the cutting process and helped us understand the type of materials suitable for lasercutting as they each have their own restrictions. In addition, the accuracy of this cutting technique encouraged more detailed and complex form, especially our second skin. Nonetheless, problems such as burnt marks and water frost on materials emerged hence, further considerations were made on the material selection. Initially, we planned to use mount board as part of our second skin because they have firm and rigid properties and ensure clean folds. However, we eventually settled with polypropylene as it is a more flexible material enough to be moulded and allow better rotational movement, which better accommodate our design.
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3.6 Reading Response Wk 7
The recent rise in development of digital fabrication technologies is generating endless possibilities for the design field to make prototypes and testings that were not feasible before. For example, the use of CAD, CAM, and CNC allows designers to transform 3D digital models into physical models directly, eradicating the need for traditional architectural hand drawing. Folding has become a major aspect in digital technologies from design to fabrication. It is a technique that transforms flat surfaces into threedimensional volume. When folding system is introduced into planar materials, those materials gain upgrades to their properties as a whole such as distant spanning, stiff and rigid, and self-supporting. By deforming and inflection, foldings is able to expand three-dimensional surfaces, amplifying the potential of boundless complex design.
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3.7 Reading applied to design
Digital fabrication has certainly been the core medium for developing our second skin. Producing physical prototypes and testing effects during the process were the most important tool to gain insights of our design and make further refinement. As we build models and prototypes, we encounter problems and find solutions while obtaining a better understanding of our project. By constructing our models on grasshopper and rhino, we were able to test and visualise our design form before sending the file for lasercutting, which have proved digital fabrication method to be more accurate and efficient. Digital fabrication was a key aspect of our design process as our second skin is made entirely through lasercutting, allowing easy assembling and dismantling of parts. From the readings, we hoped to achieve the expansion and contraction of fold to create dynamic movement by adding bigger supporting frame. Thus, digital fabrication is definitely critical throughout the development of our second skin.
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3.8 Prototype development
Prototype development Advanced Folding After more discussion with our tutor, he suggested that our second skin should demonstrate more features of folding. Making this as our new goal, we intend to blend rotational and organic movement into our design. With this, we had to reconsider our design support and the structure of our second skin. Problems We overlooked a few problems when building our shoulder support, which were: - cracking caused by compression - connections for the second skin onto shoulder support Further Development of Second Skin Due to the added feature, we had to make our second skin larger to ensure that the movement works. A sur face was created on the silhouette as shown in the photo to set as guidance for the size of our second skin. Then, the digital models were unroll surfaced on Rhino to send for laser cutting.
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3.9 Prototype optimisation
Joints To prevent cracks for happening, we developed a joint as a connector so that the other parts of the support would slot into the gap perfectly without exerting compressive onto it.
Connection between Shoulder Support and Second Skin To achieve rotational movement while still portraying organic form, it was relatively difficult for us to build. Fortunately, we managed to find our ways of representing the idea in our second skin. Firstly, we extended the height of the shoulder support and added two fixed frame to accommodate the movement. However, there will be no connections among them as they might lose the rotational function. In addition, we tied the second skin onto the rotational frame so when user rotates the second skin, the push and pull of the skin creates the organic movement.
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3.10 2nd Skin final design
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2nd Skin final design
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3.11 Fabrication Sequence
1. Excess perspex removed and ready to assemble.
2. Assembly starts from joining the left and right support.
6. Panels folded nicely following the half cut lines.
7. Panels connected together with stapler.
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3. The joints are glued together.
8. Panels arranged according to t
their own numbering.
4. Polypropylene strips attached to the fixed frame with cable ties.
5. Shoulder support complete.
9. Finishing each section.
10. Three sections put together with stapler and tied onto shoulder support with cable ties.
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3.12 Assembly Drawing
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Shoulder-support diagram
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Translucent (impermanent - Intimate to Social) wavering, uncontrollable emotions
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Black (strangers) rejection, self introspection
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White (personal distance) friendly interaction, self-confidence
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Second Skin diagram
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2nd Skin
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