YIYAO SU

Student Number: 527913 Semester 1/2013 Group 5

MODULE 3 Frabrication

Ideation and Design review

Dandelion

analytical drawing

Emerging form

From the process that I choice the natural pattern to build my emerging form, I always base on my recipe -- rotation.

All my design in the later modules are always follow my recipe

From my pattern, I find out that each dandelion are formed by many seeds which are grown by themselve and gathering toghether. The whole pattern looks formed by many light points and each one are rotate from another one.

Ideation and Design review

In making my clay model, I also relate to the recipe of rotation. Rotating the elements and scaling them into a “bar” shape. The top part is larger than the bottom

This is the initial 1;1 scale I design. However, for my final model, I find out this initial scale is not big enough to show the light effect.

In order to build my digtial model, I firstly simplify into the shape above and digital it in Rhino.

Light effect

The light effect I want to have is diffussion. As the example structure 'NOTRE DAME DU HAUT' introduced in the lecture, when the light go through the special shape of windows, it has been diffused inside. Different lightness can seen from the small side to the large.

However, this effect can only be seen own the model itself but not the outside environment. So I also want to achieve that when the light go through the whole, it can form the light hole on the ground.

In building my model my own lantern, I not only just base on my recipe but also the effect that I want to achieve. However, the light testing of my emerging form is only show the light lole effect outside the model, which haven't show the diffusssion effect, but I think it still can achieve that.

Ideation and Design Review

This 3D custom is based on the shape of my emerging form. Each pattern are build in octagon and rotated by 45 degree. As the result, each tube can have the angle between each other. The light go through each tubes and interact with each other

However, the whole model is over-exposed. When the light has been put in the lanter, the light effect may cannot come out because the light may go straight out without any obstruction.

Initial Digital model

Design Process - Prototype 1

W h e n I t r y t o m a k e t h e prototypes of the init ial model, it is very easy to collapse. So, these solid part of the model I develop in the middle and bottom parts can also support my model and make it stronger to prevent bending. Futhermore, in terms of LED light, it can be located inside.

In order to solving the problem of over-explosed, I addtwo close parts in the model.

However, when I went back to review my emerging form and initial pattern of my model, I find out the shape of the solid part do not have any connection to the octagon pattern that I build initially. As a result, the whole lantern seems seperate into four different parts.

Futhermore, when I put the LED light in partitial prototype of the lantern that I build, I find out that although the effect that I want to achieve on the wall has been shown out, the lantern itself still over-expose. Because it has lots of hollow parts, the ligh go straight out without any obstruction.

Partitial 1:1 prototype 1

Design Process - Prototype 2

Refer back to the prototype 1, since the solid part and the hollow part seems do not have any connection. So I need to think how the solid part can be combined into the hollow part.In this prototype. Fisrtly, I change my model which made from 3D paneling tool into 2D paneling tool. The 2D pattern that I use here is base on the 3D one. It can lead the model easier to make and also have the similar light effect. Furthrmore, I build the solid part base on a the flat ractangle 2D pattern and let it rotate along the whole model in 360 degree. It is not only make them connnect well, but also can relate to my receipe. Then, on the top of the solid part, I put the 3D pattern as the second layer, which can let the whole lantern can connect back to my emerging form.

3D panelling 2D panelling After I make my prototype 2, I find out some problems. Firstly, the hollow part of my model is very soft. That mean I can only hold the model from its bottom part. In this case, it is different to my initial idea (hold like a "bar"). Secondly, even through on the digital model on Rhino seems still connect to my emerging form, the 2D part actually does not have any connection with the 3D panel after I build the lantern. Prototype 2

Thirdly, when I test the light effect with the LED light, it cannot come out any diffussion effect. Because the 2D pattern does not form into a tube shape, the light cannot be diffuse through the flat hole.

As a result, this prototype stil has fail and its biggest problem is that it has been far away from my intial idea and pattern.

Design Process - Final model

Lear from the former prototypes, I find out there are three main problems that I should figure out. The first one is the lantern cannot be over-exposed and the second one is my design should has tight connect ion with my receipe, pattern and emerging form. The last one is the strenght of the model.

In terms of the over-exposed part, I find out that if I rotate the 3D panel for 45 degree, the whole model can has less hole and looks more solid. As the pictures show on the left, different angle of the pattern has can arrange into different shape of panel when I using the custom 3D panel. This final model is obviously has less hole compare to the intial model. Futhermore, when I offest the point in paneling tool, I use the command point attract. I this case, the 3D pattern on the top of the lantern is larger than the bottom part.

S o I s t i l l b u i l d m y digital model by the o c t a g o n 3 D p a n e l t o s o l v e t h e i d e a problem instead of the 2D panel.

Inital panelling custom 3D final panelling custom 3D

Design Process - Final model

Because the hole part is the tube shape, the model will be very soft without any support. As a result, learning from my first prototype, I build a strenghten layer in the middle and bottom parts which are the weakest part of the lantern.Also, these strenghten layer should have connection with the whole model. so I build a plane which is only based on the 3D panel shape.

strenghten plane based on 3D pane shape

strenghten layer of prototype 1

Unroll Cutting template

Before I unroll my model, I set each unroll part into different colours. It help me to distinguish the location of the unroll patterns from the model.

Also, because the model is unroll in row direction and they have similar shapes on the cutting card, I lable each pattern in order to easy to follow the order when I building my model.

Furthermore, in order to saving the card, I rotate the unroll pieces to lead less place has been left. However, for the last page, there are only six cutting pieces on one page, it is a kind of wasteing paper. But they cannot fix into the former five.

Strategy of making tab

A score line has been left on the contour of the cutting piece. It avoid the whole piece drop down when I was carring the cards.

The width of the tab I set in grasshopper is 5mm. Since before I set 1mm when I making the initial protopye, it is hard to stick. So it's beeter to set a wider tab. However, the tab cannot be too large, otherwise will affect the outlook of the model.

Because the pattern that I unroll is a open space, so there are two side of the tab have been remove.

This piece is one of the part of the strengthen plane in the model. When I build the panelling pattern, it is better to build a plane with any hole on it as the shape will not easy to bend. So after I unroll the pattern, I should draw the hole with black line. In this case, the card cutter can recognized. It is easier more accurate than I cut them by hand.

When I make the tab, I find out some pieces still has the overlap. But it can only be seen when I zoom in largly, and the distance between them is only about 0.01mm. So I think this mistake can be ignore and I just need to delete the useless lines.

Because the width of the tab I set is quie big, and the contour of the piece has small ange in some place, so sometime the tab will overlap with eachother. In this case, I should trim that part and draw the tab by myself to elimilate the overlap part.

Black line=cut line

Red line= score line

Meterials Usage

This quick-dry is real ly useful in making the model. Compare to the normal PVA, it take less time to dry. Also, because it is white colour, it is difficult to see on my white colour model.However, because it is dry too fast, I should make the model very quickly. Otherwise the glue become dry and I have to do it again.

In making my first and second prototype, I have use the double side tape. This tape is strong enough in connecting the big pieces togehter, but it is weak to connect the thin tab. The tension force of the model let the piece easy to seperate and lead the model fail. Also, it is easy to make the model looks dirty. The tension force of the model let the piece easy to seperate and lead the model fail.

The scotch tape cannot be used in making the model because it is definitly affect the out look of the model. However, I will use it to stick the LED light and batteries together.

Blue tack is very useful in using the glue. Because the two piece cannot stick together strongly before the glue completely dry, so I use Blu tack to wrap the tap together and save the time to wait. However, sometime the blue tack will mix with the glue. When I remove the blue tack, there are some blue pieces have been left.

This is the small size of binder clips. They are used in the same purpose of the blue tack.

Final FabricationThe inal fabriction involved cutting the unfolded template on the 900mm x 600mm white card, using the card-cutter. The quick-dry glue was used to connect the panels together.

My model has two main different parts-- the patterns with the basic layer and the patterns without the basic layer. The whole model are formed by 7 strips. The following processes I will seperate into these two parts to describe. I will mark down the strip numbers.

Patterns with the basic layer (middle and bottom par of the lantern maintain 3 strips)

1. cut the basic layer patterns from the card. should follow the number that lable on the paper

2. use the quick-dry glue to stick the tab together. In order to saving the time, use the blue tack to hold them unit the glue dry.

3. follow the second step, the whole row strip are made up by 7 patter. But doesn't not need to connect the head and bottom in this step

4. start making the upper layer of the this par. Get the pieces from the card follow the numbers.

5. Fold the pattern followed the score lines. Each patterns can be fold into two octangon tube.

6. Fold the bottom tab of the pattern get from step 5, and stick to the basic layer from step 3. The first two tubes should be started on the fisrt part of the layer in step 1. Also use blue tack to hold them together.

Final Fabrication

7. Repeat step 6 and first finish the left side the the strip and then do the right side of the strip. But when I constructe the right side of the strip, I start from the bottom of the strip because it's more convinient from the bottom part. A

8. After finish this whole strip, the head and bottom still doesn't need to connect together in here.

9. start making the part with basic layer on the bottom part of the model. Similar to the middle part in the former process, this part also construct the basic layer first and make the 3D pattern secondly. Repeat the same process from step 1 -8.

Patterns without the basic layer (only construct by 3D pattern, maintain 4 strips )

1. Smilar to the step 4 and 5 above, in this process, I only need the make the 3D patterns.

2. After construct contruct 2 groups of the connected 3D patter, use glue to connect the tap between it into the shape the photo show above.

3 . R e p e a t s t e p 1 a n d 2 , construct the first whole strip with 14 groups of 3D patterns. Have to remember mark down which end is the first group.

4. Repeat step 1, 2, and 3, construct the second strip with another 14 groups of 3D patterns. After that, stick the side of these two strip together. This get the top part of the model.

strip 3 strip 4strip 7

strip 1 strip2

Final Fabrication

5. Repeat step 1, 2, 3 and 4 to contructed strip 5 and 6

strip 5

6. Use the same method in step 4 to connect the strip 1, 2, 3, 4 and 5 toghether (both the part with and without basic layer)

strip 5 + 6

7. used the same method in step 4 to connect the strip 7 to the rest part of the model. However, in this step, because the size of strip 7 is smallest, it is hard to used glue to stick them toghter so I use the binder clips to hold it until the glue dry.

8. The final step is connect the head and end of each strip together. It is better to connect the smallest strip first because there are larger space for the had to inser in the model to set the glue.

Final model

Size of the lanternlength: 51.8 cmWidth: 28.1 cmHight: 23.7 cm

Light construction

1.prepare the turn on/ off tab by card paper, and fold the end. It is easy to pull when the light has been set in the lantern.

2. Insert the on/off tab in between the LED's wire and the + terminal of the battery.

3. stick another tab on the tape. Place the tape over the LED and battery, matching up the former tab so that there is a piece on either side of the LED wire. So the bottom tab can be pulled later with the fold up part.

Because I only need to construct 2 LED light in my lantern and my lantern form a open space, I have construct the electric circle. I connect the LED and batteries with the simple switch

4. When I pull down the on/ off tab, the LEd has been light

5. I make two set of the LED light with batteries. And stick a tape on them which can be use to stick on my lantern.

One LED has been set on the bottom of the lantern

Another LED has been set on the middle of the lantern.

Both of them are set on the part which have the basic layer. The layer have the ability to hide the LED.

Light Effect

My lantern really show the light effect that I want to achieve. The ligh go through the tubes from the inside of the lantern and difuse out.

Also, the effect looks similar to my natural pattern. Each center hole of the tube has different effect with other parts, which similar to the seed of the dandilion.

In additon, because each tube has been rotate and form different angles with each other, it related back to my recipe 'rotation'.

Light Effect

Assembly Drawing

This assembly drawing show a fragment of my model. Connecting each pattern togeter can get one strip of my lattern.

The thickest lines show the hole of the model.The thin lines show the the fold part of the model.Desh lines are the connectors of each pattern.

Assembly Drawing

This assembly drawing show a fragment of my model. It show how two strips can be connected

The thickest lines show the hole of the model.The thin lines show the the fold part of the model.Desh lines are the connectors of each pattern.

ReflectionKolarevic, B 2003, Architecture in the Digital Age – Design and Manufacturing, Spon Press London.

The article by Kolarevic Branko introduced the important of digital production in contemporary design. He describe that using digital can ensure a high degree of precision in fabrication and assembly. I agree with him. For example, in our project of the lantern, if we design the lantern without digital fabrication, the lantern cannot be made in accurate. Furthermore, Kolarevic said that digital technologies are not only for conception but also as a medium of translation. When we making our own lantern on the computer, we should have the initial idea and shape of the model in the mind first and followed by translate to digital form. The process of translating from digital to physical can lead the designers becoming more directly involved in the fabrication process, as they create the information that is translated by fabrication equipment. Kolarevic has introduced some common three-dimension fabrication technique – plasma-arc cutting, water-jets and laser- cutter. The biggest differences between these techniques are materials they used for cutting and the capacity of the thickness they can cut. In Fab-lab, the card-cutter is another kind of fabrication technique. I think it is a simple technique. It is worked by the movement of a needle. The depth it can cut is more depended on the numbers of the speed and force that we set.

After we get the jobs from the cutter, we start the process called formative fabrication. In order to connecting them into the form that we need, they should be deal in fold or any other action. However, the shape may be changed through reshaping or deformation. For example, because of the paper that we use to construct the model is soft, bending or deformation may occur when we try to connecting each parts together. Also, since the glue that we used to stick can soften the paper, the shape may also become not very accurate. But I have to said digital three-dimension models is really helpful in assembly. For example, after we unroll the model and label each component and cut them in the paper, the components have the precisely location and can be fix in its proper place. The physical form of my lantern has been constructed in the exactly same shape as the digital one.

Another amazing process that Kolarevic has introduced is an inverse process – from physical to digital. The machine can scan the physical object and model it on the computer. This technique is useful in detecting the deviation of the building or any other objects from the geometry of the digital model. Especially, it has been used increasingly on construction sites to quickly measure distance and determine locations for the installation of various building.

Furthermore, I think the digital technique is important in the architecture process. Traditionally, architects used tape or other devices to locate the building component on site. However, nowadays, the new technique can precisely determine the location of building components. In addition, 3D printer was used to produce components with complex, curvilinear geometries in series but not big component. Recently, a frilly additive technology called contour crafting was introduced to manufacture large-scale building components directly from digital data. In other words, it improves the speed and precision in building the structure.

Reflection

Iwamoto, L 2009, Digital fabrications: architectural and material techniques, Princeton Architectural Press, New York.

The second reading by Lisa Iwanmoto (2009) is talking about digital fabrications. As she said, digital media is a very important process in design. I cannot imagine designing without computer software. Like Rhino software, which is used in design our lantern, combines our idea into a three dimension model on the computer. However, the digital design still has some differences with the constructive processes. Iwanmoto demonstrates that “This computerized process streamlines production – effectively blending upstream and downstream processes that are typically compartmentalized, often eliminating intermediate steps between design and final production” (2009, pp.5). This means that when I build my prototype, I should always review my digital model and make some improvement which based on the initial one. For example, the digital model that we make in Rhino doesn’t show any gravity effect. Actually, when we construct the model by hand, we should consider the gravity effect that the model gains. It may collapse. In addition, Iwanmoto also mentions material access in design. The digital fabrication by Rhino doesn’t show the material property, but material is also an important factor in the construction. Such as the card we use on the lantern though is stronger than the normal paper, it is easy to fail if we don’t design it carefully.

Furthermore, Iwanmoto describe how tessellation has been used in design. Tessellation is a collection of pieces that fit together without gaps to form a plane or surface. For instant, Buckminster Fuller’s geodesic domes are early examples of the used of tessellation. He used the triangle and hexagon to construct the spherical shape. Similarly, I build the base surface of my model based on many different triangles and combined them into the shape that I need. This is because triangle is a stable shape. When they cover along a face, each plane cannot be twist. In here, two primary ways to model three-dimensional forms digitally has been introduced in the reading – NIRBS and meshes. I also used this method in the paneling tool. I tried that if I straight build the panel with plane, the plane would be bended. So I should build it in meshes and used Mesh-to-NURBS to rebuild my model.

Lastly, Iwanmoto indicate that folding turns a flat surface into a three-dimensional one. It is really show on building our own lantern. After we unroll and cut the piece out, we need to fold it into the 3D shape we need. But I find out some limitation when I fold my model. After I get the piece that the cut cutter scores the red line (fold line) that I indicate on the software, I try to fold it into a 3D shape. However, the angle of the shape is easy to change. Sometimes this may the cause of collapse.