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DIGITAL DESIGN + FABRICATION SM1, 2016 Sleeping Pod

Melanie Yard (757729) Lyle, 08

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Contents:

1.0 Ideation 1.1 Object 1.2 Object + System Analysis1.3 Sketch design proposal

2.0 Design2.1 Design development intro2.2 Digitization + Design proposal v.12.3 Prototypes and Personal Space 2.4 Precedent research2.5 Design proposal v.22.6 Prototype v.1+ Testing Effects

3.0 Fabrication 3.1 Fabrication intro3.2 Design development & Fabrication of prototype v33.3 Week 6 Readings 3.4 Design development & Fabrication of prototype v43.5 Material Optimisation3.6 Final Digital model 3.7 Fabrication sequence3.8 Assembly Drawing3.9.1 Completed Model v 13.9.2 Completed Model v 2

4.0 Reflection.

5.0 Appendix5.1 Bibliography 5.2 Credit

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0.0 Introduction

The Brief calls for innovative design of a secondary skin or envelope that is wearable and accomodates the body. The envelope must be a 3 dimensional volumn that will explore, measure, and/or negotiate the boundry of personal space

You will design a sleeping ‘pod’ or devices for 1 person. While sleep in the work place is seen as counterproductive, recent research has shown that powernap can increase brain function and productivity at work. The pod or device will allow 1 person to take a powernap in the univeristy campus.

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91.0

Idea

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1.1 Object

Photograpghs of fan used and measured drawings used to extrapolate the rule of the fan

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The object chosen for this assignment was the fan. To extrapolate a rule of how the fan worked numerous observation methods were employed. Photography was the first step to this whilst extensive measured and orthographic methods followed. Due to the fact that i had no knowledge of Rhino or other forms of CAD software systems it took awhile to draw up the fan on the computer.

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1.2 Object & System Analysis

To create a design that follows the Panel and Fold system of the fan a rule had to be estab-lished to understand how it works. After direct observation, measured and orthographic draw-ings had taken place it was found that the pin followed the same system: A series of panels reolving around a pin to create a larger volumn. With this rule in place sketch designs could then be drawn up.

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Once i commenced drawing and observing the object i realised it was quite a com-plex system. One reading that allowed me to easliy pull apart the object to under-stand its basic rule was “How to lay out a croissant” by Miralles and Pinos. Here they demostrated that although seemingly easy it can be incredably complex when broken down.

Images taken from “How to lay out a croissant” by Mirralles and Pinos

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1.3 Sketch Design analysis

After the rule of the fan was extrapolated sketch designs could be drawn up. By creat-ing small sketch models exploring how to create volumn through the rule found that i chose to focus on achieving transparancy within my designs. by twisting the panels and attaching them differently i found i could create large volumns with thin members of the fan. It was here i realised that the final design would have to be dynamic in nature for it to match with the rule of panels rotating around a pin.

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Dalian International Conference Centre by COOP himmelb architects.

To create transparancy with the panels i looked for precedents to help understand how i could bring this element into my design. I found the Dalian International Conference Centre to be quite useful. The panels on the facade of the building twist in different direc-tions and certain points to allow for transparancy and a sense of movement across the surface.

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2.1 Design Development

Beginning the group work we began by finding common denominators in our work. Our sketch drawings revealed four main areas that we were keen to explore: a tree system of panels connected by pins, a series of panels rotating around a pin to create a larger volume, and the effects of transparency and movement.

1: Sketch Design, 2: Sketch Design by H.Wang, 3: Panels showing transparancy, 4: Sketch Design by H. Wang

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By combining both ideas together the first proposed design revolves around the repetition of the same form. We began to explore the idea of using multiple panels and pins to create volume around the human form. The final form is a structure that wraps around the shoulders to pro-vide protection on the side of the head and supports the back from the base of the spine. This sketch design was carried out in a Rhino model.

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1: Singular panel, 2: Panel Connections, 3: Sleeping Pod Design 1, 4: Sleeping pod Design 2 by H. Wang

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2.2 Digitilization & Design Proposal v1

21Images show rendered 3D Rhino model of Proposed Design v.1

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2.3 Prototypes and Personal Space

To understand how the sleeping pod works around the body we first had to under-stand how the subject would sleep. Initially the pod was designed for a subject to lean back into when sitting down. After personal space mapping had been under-taken however, the design changed to accommodate a student laying down on a desk. This position was chosen as it was the most common position for a student to sleep in when analyzing university students.

1: Sketch Of Personal Space, 2: Personal Space by H. Wang

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Through sketch prototypes the design was able to progress signnificantly. We ex-plored how each panel could be made, such as small blocks rotating to form one panel and longer spanning panels. Long singular panels were found to be the most efficient form of panel to use whilst still spanning the space we needed. Later on how-ever in M3 smaller panels were revisited and used for the final model.

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2.4 Precedent Research

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1: Digital Wave by P. Skewes, 2: Digital Wave by P.Skewes

Although this precedent does not use a panel and fold system it was used as a precedent as it has key features which we wanted to achieve in our design and offered a logical solution to how to achieve them. The transparency achieved through the spacing’s of the weave and the ability to change this created movement throughout the surface of the design. We discovered we could reach the same affect by placing panels closer together and further apart across the design. The material of this system however would not support our own design as seen in later prototypes paper could not hold the weight of the pins.

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Transperancy was a key idea from the begining of this project yet we did not know how to tranlate this into our design. The presedent showed us that if we placed the horizontal panels at different sections (some closer together, others further apart, that we could achieve our goal of transper-ancy.

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1: Transparency and Personal Space side, 2: Transparency and Personal Space top view, 3: Sketch of panels with transparancy

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2.5 Design Proposal v.2

The desired effects of the sleeping pod are to create a sense of comfort for the person us-ing it whilst providing protection on the outside. To achieve this the inside of the panels are smooth as opposed to the outside with extrusions, spikes and bumps.

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1: How panels move back and forth by hac Wang, 2: scale on body by H.Wang, 3: Back Piece H. Wang

27Final Rhino Images used for Prototyping

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2.6 Prototype v.1 Testing effects

This prototype was the first to use lazer cuting techniques. To understand what material qualities we wanted our final piece and to understand how the materi-als behave we chose to cut MDF, and both clear and white perspex.

29Prototype for M2 Final

Key things we learnt from this prototype was weight of materials, the brital na-ture of perspex and how difficult it would be to connect all the long panels together into a movable piece.

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Following the feedback given to us from our M2 module there were many issues that we had to address to push our design from a 3d Rhino model to fabricated final sleeping pod. Feedback given suggested we shorten the structure to elevate weight, pins still had to be designed and the detailing how each of the panels comes together on the back needed to be finalized.

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1: 3D Rhino model from previous module , 2: 3D Rhino Model from previous module by H.Wang

3.1 Introduction

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In response to the feedback given from our M2 work, the first Rhino model was made for the M3 unit. In-stead of using long panels that span over all of the person, we chose to section them. The idea was that when the user is standing up the panels fall flat against their back, when they move the panels over their head however the panels fold over and are locked into a position (that is individual to each panel) and form a large volume around the user as they lean on a desk. To accommodate this 3-6 smaller panels were used to form a larger one which could rotate between a volume and being able to be flat.

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1: 3D Rhino model reconfigured for M3 by H.Wang , 2: 3D Rhino Model reconfigured for M3 by H.Wang

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The design required a pin that restricted the motion of each panel. Each panel had to be able to lay flat and create a large volume, to accommodate this a pin had to be designed. A small 2mm thick Perspex circular pin was created with a hook coming out of it (seen as above). This pin sat in between the two polypropylene panels of which each had a cut out which restricted the move-ment of the pin (customized for each panel). To stop the pin coming out of the panel circular polypropylene larger than the pin were added to the sides of the panels. These were demonstrat-ed in our Prototype V.2 and 3

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1: Deatil of pin rotation, 2: Pin rotation on prototype open, 3: Pin rotation of prototype closed.

3.2 Prototype Development v.3

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To explore our design further, different sizes of panels were experimented at 25,20 and 15cm long. We found that for our design it was best to use a combination of larger and smaller panels. Our final V.2 Prototype (as can be seen above) uses 15cm panels and 4 pin’s, this was the first successful use of our pin and panel system.

Differnt sized panels that were explored

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Architecture in the Digital Age - Design + Manufacturing/ Branko Kolarevic, Spon Press, London c2003

In Kolarevic’s book Architecture in the Digital Age- Design + Process he discusses the many ways in which digital fabrication can be utilized for building construction and how it has influenced and changed ar-chitecture in the digital age. Kolarevic mentions a few fabrication processes such as two dimensional, subtraction, additive and formative fabrication. The technique that our prototype has been utilizing is the two dimensional or CNC cutting. By cutting a flat surface into panels, and using specialized pins we have been able to create of volume. Laser cutting was used as the sheets we were cutting where quite small and from the initial design phase we wanted flat panels.

1 & 2: lazer cutter in action from Kolarevic’s Architecture in the Digital age

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3.3 Week 6 Readings

371: Sequence of consturction by H.Wang, 2: Panel connection by H.Wang

After the reading it was realized whilst we were using CNC/2D cutting meth-ods we did not have a way to identify where each piece was going in the design for the assembly. Kolarevic mentions that you can code and mark each piece to know where it goes in the design. From this we etched a mark on each panel with a code to know where it goes when it came to final as-sembly.

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Due to the arcs and volumes created by panels of the same length we found it hard to close the space. To close the holes, different sized panels were used. The next step in our prototype development was to change the shape of the panels to create more move-ment across the surface of our sleeping pod. To do this we had to re design each panels so it was different. This can be seen in our prototype V3.

1: design overlay on body, 2: Sketch design of new panel.

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3.4 Prototype Development v.4

391-5: Prototype V.3 and design solutions that were explored.

Each panel had a position to be in when all the panels when curved. Through our proto-types however we found that they fell over and did not hold their position. To fix this numer-ous solutions were explored including a grooved plate, which the panels fit into, small box structures between each panel and a slit between each panel of which another panel could fit in-between. None of these solutions however worked.

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Prototype V.3 began to explore the idea of putting curves or a pattern on the panels. Whilst keeping personal space in mind we wanted to create an outer panel appearance of defense whilst the inner sides of the panels created a sense of peace. The side of the panel that is closest to the user is smooth to achieve this sense of peace. The side of the panel that faces the outside however had special detailing to achieve a defensive effect. This detailing was inspired by the line of a cardiac electro gram: the line your heart makes when connected to a monitor. This line was used all over the design with it only ever being repeated twice

1: An cardiac electrogram, 2-3: Line used on panels.

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41Effects created by using the cardio electrogram lines as inspiration

The final model had a total od 230 clear pins, 460 circular joins and 234 panels, all of which had to be precisely cut. To ensure the quality of these instead of hand making them a laser cutter was used. With each panel being a different shape and having a different angle for the pin, this made it difficult to connect them. To simplify the process a system of how to make each pin connection was made and can be used for every pin that had to be built.

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Due to the size of our project, with every panel having to be lazer cut, ma-terial optimization was a key factor we had to consider. To save time all our panels and pin section were lazer cut, to do so all our panels were placed on a cutting sheet template.

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1: Template used for FabLab lazer cutting for M3 final by H.Wang

3.5 Material Optimiztion

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To make the most of our materials the panels on the template were placed as close together as possible to save material wastage.

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1- 2: Template used for FabLab lazer cutting for M3 final by H.Wang

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3.6 Final Digital model

45Final 3D Rhino Model for M3 Fabrication by H.Wang

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3.7 Fabrication Sequence

47Fabrication sequence

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3.8 Assembly Drawings

49Assembly Drawings by H.Wang

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Although extensive prototyping and testing occurred, our final sleeping pod did not work as intended and required extensive work that was not included in the 3D mod-el to ensure it worked for presentation. Using a polypropylene material to achieve our desired effect we did not consider how flimsy this material would be.

3.9.1 Completed model v.1

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Whilst the prototypes using the polypropylene worked, on mass they did not hold their own weight. To fix this, an orange MDF bracing system was attached. Due to this we chose to rebuild our model in Perspex for our final photo stage. Those fol-lowed all the steps as the previous model however with a material that could hold its own weight and could move back and forth as an individual panel and as a whole

Final model for M3 presentation.

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3.9.2 Completed Model v 2

Our final model out of Perspece proved to be much stronger and held its own weight. A clear perspex frame was still included however as we found it to be the only way to ensure panels fell into the correct position.

53Photograpghs by Melanie Yard

Although we thought we considered all aspects of the design, in this final sleeping pod we still found is-sues such as the perspex being brital and snapping or in the circumstances of the longer panels not being able to bend with out assistance.

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55Photographs by H.Wang, Model: Melanie Yard

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Through out this process I had no idea how design solutions to critical issues could impact the design of the final form as much as they could. Initially when given the fan as an object I was convinced there was no way to produce anything from it. Through measured and orthograph-ic drawing however I was able to extrapolate the basic rule and was able to move past this stagnant form of thinking. The reading “how to lay out a croissant” demonstrated how to do so, although seemingly simple it captured its true complexity through orthographic drawing. Through drawings and other observation methods a basic rule which was carried throughout the design process was formed: a series on panels rotating around a pin to create a larger volume.

4.1 Reflection

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Starting the group work, Hac Wang and I began to find common de-nominators in our work to find a base for our design. Both of us found the same rule of the fan and by combining sketch designs we cre-ated a sleeping pod that sat on the shoulders. A lecture that affect-ed Hac and I was on effects, from this we identified key aspects we wanted in the design including varying degrees of transparency and movement across a surface. From the beginning an important part of our design was for it to be dynamic with panels rotating around a pin. In hindsight this was our downfall and caused many problems such as:

1. What pin could you use/how can you use a pin to rotate the panels but only to certain degrees: controlling the rotation2. What materials to use due to the weight of the structure3. How to fabricate over 200+ panels and pins and know how they all go together. 4. How to design a panel that is aesthetically pleasing and re-sponds to personal space5. How each panel connects at the back.6. How they can all move independently of each other with out crossing over when moved in between positions.

To solve these issues, several prototypes were made and a successful model with rotating panels was made. This highlights the importance of prototyping and iterations with in the design process as our design changed each time we solved issues such as the pins. Many solu-tions to our problems came from the readings such as B, Kolarevic’s Architecture in the Digital Age. Here I learnt how important it is to label your work to know where each panel and pin goes with in the design. Kolarevic also explained how this is used on a larger scale in regards to the construction of a building: were each piece is barcod-ed to know its exact position. This was replicated into our own design where by when our model was being laser cut each panel had a number and a letter dictating its position in the design etched into it.

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Solving these problems to try and find the most optimal and elegant solution to our design meant the design process was not linear. This was particularly relevant for the 3rd module: Fabrication, where numerous prototypes were used to test the pins and aesthetics of the panels, going back and forth between prototypes and pulling out aspects that worked to move forward. It was in this module that we learnt that al-though the design works well in a 3D format it will not always translate the same way into a prototype. Although 3D software allowed us to solve many design complica-tions it also cause many as well. Some of which that are not always in your control, such as when a design is laser cut the quality of the work can be compromised or not done correctly. Although our outcome was a complicated design due to a simple making rule we were able to create a sleeping pod that relates to personal space and provides protection from the surrounding environment.

Throughout both the lectures and tutorials, the element of craftsmanship was empha-sised. In the week 10 reading, (Building the Future: recasting labour in Architecture) craftsmanship was defined in relation to modern work as the “ process of mediating not only between tools and the objects that are produced but also between design as a process of imagination and a production as a process of technique”. This can be related to my own work as I have learnt that the skills required to use CAD software systems were indeed a technique and skill that required time and patience to learn and become proficient in. This is also linked with an interview that was shown in the week 11 based on Rifkin’s book The Third Industrial Revolution on the third industrial revolution. As future designers it is important to keep in mind how we can adapt our designs and the process of making them in regards to energy and material usage. Due to the extensive design process of using prototypes to test mechanical systems their was a lot of wastage of materials. However without the use of CAD software systems this process would have been much more extensive and produced a larger amount of waste.

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Reflecting on the process of this semester it was a translatable learning curve. Many of the skills I have taken away from this course will help me for future projects. The three main things I have taken away include: An Increased knowledge of CAD programs including not just Rhino but also Adobe InDesign, Illustrator and Photoshop, learning that the design process is not always linear and can often be a chaotic mess due to time constraints and finally that time and money constraints hinder the design at an early stage. I am proud of the final results and that we have kept the main elements of the design that we thought were important from the beginning: transparency, move-ment and a dynamic design whilst still using the fundamental rule we discovered in M1 Ideation.

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5.1 Bibliography

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Enric Miralles,Carme Pinos, 1988/1991, “How to lay out a croissant” El Croquis 49/50 Enric Miralles, Carme Pinos, En Con-struccion pp. 240-241

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 Architec-tural Press. pp 38-42

Sommer, R. 1969. Personal space : the behavioral basis of design / Robert Sommer. Englewood Cliffs, N.J. : Prentice-Hall, c1969.A

Rifkin, J 2011, The third Industrial Revolution. Palgrave Macmillan.pp107-126

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5.2 Credit

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