MODULE 3: FABRICATION

LIM BINXIU ANGELINE596462

VIRTUAL ENVIRONMENTS

MODULE 1: IDEATION

First, I chose a natural object – a seashell. From there I abstracted the curves and the vertical lines of the seashell as a guide for my analytical drawing. I also created a recipe to explain it. This 2D drawing is then translated into a 3D form using extrusions of skewed triangles in paper.

MODULE 1: IDEATION

I then made emerging forms in plasticine and explored different ways of interacting with the hand.

Concepts for development:

1. Growth2. Rotate3. Overlap

MODULE 2: DESIGN

Using the concepts discussed in Module 1, I decided on a composition strategy for my design, which is to have an origin point with a spread out and flowy effect (can be achieved through curves). I did a few forms before settling on the final form on the right and translating it into Rhino (below).

MODULE 2: DESIGN

I tried many paneling options but eventually focused on 2D tribasic and 3D pyramid as they both consist of triangles which is relevant to my analytical drawing. Another area I explored is the pt offset border command.

MODULE 2: DESIGN

During the fabrication of the prototypes, I explored having double skins through covering the 2D panel with a 3D panel. The idea of the double skin could also be achieved through not cutting out the entire piece using the pt offset border function and folding down the flaps.

MODULE 3: FABRICATION OF PROTOTYPE 1

I did a partial fabrication of my first prototype which consists of a 3D offset border pyramid panel over a 2D offset border tribasic panel. However, the lantern is too over-exposed and there is no place to conceal the lights. Although it produced the shadows effects of variance in thickness and depth, I realised that I should be focusing on the illumination of the skin of my lantern instead of the shadow effects it can produce.

FABRICATION OF PROTOTYPE 2 – RHINO PANELING

I find my previous model too rigid as the rings are just protruding outwards. I tried to explore ways to create leaning and overlapping effect through stacking of paper models. I then went back to Rhino to edit the model by moving the 2nd grid offset forward instead of a direct projection upwards. And then applying the pyramid template to achieving this skewed pyramid effect. After which, I added another layer of pyramids with a smaller grid offset and straight protrusions to blend both the different surfaces together.

Tribasic panels Pyramid panel (direct extrusions)

Skewed pyramid panel (Moving 2nd offset grid forwards)

FABRICATION OF PROTOTYPE 2

These pictures show the fabrication process of my model. I unrolled the pieces in rings and then joined them together.

FABRICATION OF PROTOTYPE 2 – IDENTIFYING PROBLEMS

I did not manage to construct a full scale prototype due to the following problems that arose during the construction.

Problems:

1.Scale of the model is too small and there are too many panels, making it difficult to construct.

2. Tabs are not glued consistently, leaving unsightly marks under lighting.

3. It is difficult to close up the pyramids because the scale of the model is small and the tabs are too narrow.

4. It is difficult to close up skewed pyramids as the slanted angles are too steep.

FABRICATION OF PROTOTYPE 2 – STRENGTHS FOR DEVELOPMENT

Strengths for development::

1. Within a single pyramid, I found that the pyramids not being able to close up interesting as it creates cut light and a layered effect.

2. Looking at an entire ring, I tried gluing down alternating panels to the adjacent panels and it enhanced the layered effect. However, I did not implement this in my final design as it only works well having many small panels. In my final design, I actually increased the size of my model and reduced the number of panels.

Stick to neighbouring ring.

Do not stick to neighbouring ring.

FABRICATION OF PROTOTYPE 3 - RHINO

I did a third prototype and this time I increased the scale of my model as well as reduced the total number of panels by half. I kept it more simple by doing direct pyramid extrusions instead of having skewed pyramids.

FABRICATION OF PROTOTYPE 3

FABRICATION OF PROTOTYPE 3

FABRICATION OF PROTOTYPE 3 – IDENTIFYING PROBLEMS

Problems:

1. There is too much 2D panels, making the top part of the model chunky and the bottom part very plain.

2. The bottom twist could not be connected well. I took note of when to change from joining a single tabs to joining two tabs together (left).

3. The flaps of the panels were in random directions and not standardised due to the way of unrolling (right).

4. Glue should be used instead of double-sided tape which tends to fall out after a while.

FABRICATION OF PROTOTYPE 4 - RHINO

I added three rings of extra closed pyramid panels (in purple) to achieve a better balance between 2D and 3D panels. I feel that this design is combination of my precedence(Al Bahar Towers in Abu Dhabi) during day time and night time as it has a mixture of closed surfaces and open panels.

FABRICATION OF PROTOTYPE 4.

FABRICATION OF PROTOTYPE 4.

FABRICATION OF PROTOTYPE 4 – IDENTIFYING PROBLEMS AND IMPROVEMENTS.

Problems and solutions:

1. Growth was not emphasised as the extrusions of the pyramids were not high enough. I increased the height of the 2nd grid offset so that the pyramids would be taller.

2. Flaps were not in the same directions. I manually move unrolled surfaces and join them to different adjacent pieces (right).

3. The electric circuit could not be placed into the model due to the curves and the small openings.The electric circuit had to be built while making the model.

ELECTRIC CIRCUIT

I constructed my circuit in parallel so that I can build a section of my model then attach the LEDs and build subsequent section and then attach the LEDs. As the circuit is parallel, the bulbs will be independent and disruptions in a single branch will not affect the rest. I also taped the wires to the tabs so that the bulb will in the centre of the model.

FINAL MODEL - UNROLLING, NESTING, TAGGING AND CREATING TABS

I unrolled my model and tagged different surfaces so that I can identify them and piece them together.

Final model

FINAL MODEL - ASSEMBLY

I created my model by unrolling in rings for the 2D panels and unrolling the 3D pyramids in groups of three or four.

FINAL MODEL - VIEWS

TOP VIEW

RIGHT VIEWFRONT VIEW

PERSPECTIVE VIEW

FABRICATION OF FINAL MODEL

FABRICATION OF FINAL MODEL

FABRICATION OF FINAL MODEL – INDIVIDUAL PANELS AND PARTS

The following pictures shows the different panels used for the whole model. There is a transition from 2D to 3D and closed to open panels to symbolise growth. It starts with the simple tribasic panel, then moves towards an offset border. Next, I experimented with cut light through closed 3D pyramids. I then moved on to offset border and making cut outs through the pyramids. Lastly, the panels are folding down flaps.

FINAL MODEL - LIGHTING AND INTERACTIONS WITH THE HAND

READING RELFECTION

Briefly outline the various digital fabrication processes. List constraints and opportunities provided for you through the use of CNC cut cutter or laser cutter?

There are a few digital fabrication processes, namely 1. Addictive Fabrication. 2. Subtractive Fabrication. 3. Transformative Fabrication.

1. Addictive FormationIn the first process, layers are added one on top of the other and is referred to as layer manufacturing. An example is 3D printing. In my fabrication, I unrolled my model in rings and I stack them up in layers. Although, this is a useful and organised way of assembly, it is important to pay attention to the joints between the different layers. In my model, the tabs were not well connected or could be seen under lighting.

2. Subtractive FabricationSubtractive fabrication is simply taking away pieces or sections from the original material. The card cutter uses this function. In doing so, we are able to get precise cut outs of our model and through tagging the pieces, we will know where each individual piece comes from and we will be able to assemble them together. This also allows us to create curved surfaces through the use of paneling tools. However, good understanding of material properties is necessary for the assembly process as paper may not bend in the exact direction that we want it to be. This fabrication method is not only limited to a 2D objects like paper but it can also be applied to 3D objects through machines with 4 or 5 axis.

3. Transformative FabricationIn this process, objects are being manipulated through certain chemical or physical reactions. I think that this is a more scientific way of fabrication.

Once all components have been fabricated, the next step is the assemblage process. Brace frames can be used to support a building, likewise, I can consider using a 2D skin to support my 3D extrusions. Another method of production discussed in the readings is the use of lofting to create ribs for supporting the structure.

I feel that there is a shift in the use of digital technology for design due to the convenience of paneling tools and tessellations. It allows us to create tessellations that can be constructed through standard templates and even allows us to come up with our own patterns. In the past, the tessellations have to be manually drawn and calculated precisely before it can be constructed. This is similar to the analytical drawings that we did in Module 1, where we had to come up with a recipe. Through computing programmes in the digital world, we are able to obtain more accurate tessellations and their shapes and sizes can be varied through methods like point attractors.

I find that the fabrication process actually helps me to understand me lantern better. Because, everything can be done so effortlessly in Rhino, I kept adding more and more components to my model, making it cumbersome and difficult to construct. I also feel that I have too many ideas and explorations but I did not actually focus on developing and making a single panel. Having too many components can also be too distracting and limiting my design to one or two paneling tools would make it simple but neat.

In addition, I also failed to consider the aspect of actually physically constructing the lantern. I always thought that whatever I see in Rhino would be my actual model in real life and it would be easy to construct. Through the fabrication process, I realised that even the simplest 2D tribasic panel is difficult to construct due to the curves in my form. I neglected the bending properties of the paper and the joints and tabs between strips of paper.

However, the fabrication process is did help me to unleash ideas and opportunities that cannot be visualised in Rhino. For instance, the folding of flaps downwards in my pyramid design and the connecting of alternating flaps. Therefore, I feel that creating prototypes is very important to test out material properties and I should not just limit myself to what I can do in Rhino.

Describe one aspect of the recent shift in the use of digital technology from design to fabrication? How does the fabrication process affects your lantern construction?