DIGITAL DESIGN + FABRICATION SM1, 2016 M3 JOURNAL - SLEEPING POD

Melanie Yard & Hac Wang (757729 & 743428)

Lyle + 08

Introduction

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.

Final Rhino module for M2

Design development

Reconfigured Design for the begining of Module 3

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.

Design development + fabrication of Prototype V.2

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 movement 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 demonstrated in our Prototype V.2 and 3

Detail of pin rotation Details of pin rotation on Prototype V.2

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 larger panels. Our final V.2 Prototype (as can be seen above) uses 15cm panels and 4 pin’s, this was the first suc-cessful use of our pin and panel system.

Differnt sized panels that were explored

Reading Response Wk 6Architecture 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?

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.

lazer cutter in action from Kolarevic’s Architecture in the Digital age

Reading applied to designHow does the fabrication process and strategy effect your second sleeping pod?

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.

Sketches of our lazer cutting and connecting solutions

Prototype development

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.

Image 1: design overlay on body. Image 2: Personal space. Image 3 Sketch design of new panel.

Prototype V.3

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.

Images showing Prototype V.3 and design solutions that were explored.

Prototype optimisation

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

Image 1, An cardiac electrogram, Image 2 and 3, Line used on panels.

Effects created by using the cardio electrogram lines as inspiration

Prototype optimisation

The final model had a total od 230 clear pins, 460 circular joins and 234 panels, all of which had to be pre-cisely 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.

Images of all the pins, circular joins and panels

Prototype optimisation

Due to the size of our project, with every panel having to be lazer cut, material op-timization 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 tem-plate. To make the most of our materials the panels on the template were placed as close together as possible to save material wastage.

Sleeping Pod final design

Left to right from top to bottom: Back, Front, inside, elevation right detail of panels 1, detail of panels 2.

Left to right, top to bottom: Front with model, Perspective with model 1, Perspective with model 2, Perspective 3, top with model.

Fabrication Sequence

Image 1-6: Sequence of fabrication in order from right to left, top row to bottom row.

Assembly Drawing

Image 1: exploded diagram of panel sections. Image 2: exploded diagram of connections to shoulder.

Image1,2 and 3: How pins connect and rotate as a whole. Image 4 Flat panel and pins at rest. Image 5 Different size and number of panels as seen in final

SLEEPING POD

Final model images

Final design close up images

Final Model Design Issues

The prototypes that were made were only 4-5 panels long and worked without any issues. The final model however was 60 panels all together, due to this, many new issues arose and solutions that worked for previous prototypes no longer worked due to the size of this final model. Although all aspects were considered prior to fabrication these unforeseen circumstances meant we had to hand make solutions such as threading met-al supporting rods through the structure, this required us to burn holes in the panels. In the end however this method was not successful.

Image 1 and 2: Final model not working. Image 3,4 and 5: one solution explored to fix problems

Factors that were out of our control when it came to the craftsmanship of the design included the fabrication of the panels when sent to the FabLab. Burn marks, melting of the polypropylene panel edges and not being cut correctly in some cases causing breakage was a common occurrence seen throughout 70% of the panels.

Image 1:singeing of plastic. Image 2 Burn marks on panels