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DIGITAL DESIGN + FABRICATION SM1, 2016 THE SLEEPING POD PHAM Hoang Phuong Trinh

784173Joshua Russo- Tutorial 7

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CONTENT

0.0 INTRODUCTION

1.0 IDEATION 1.1 Object Measurement 1.2 System Analysis 1.3 Reconfiguration 1.4 OutcomeandReflection

2.0 DESIGN 2.1 Design Development Introduction 2.2 Digitalization + Design Proposal V.1 2.3 Digitalization + Design Proposal V.2 2.4 Design Proposal V.3 2.3 Precedent Research 2.4 Design Proposal V.4 2.5 Design Proposal V.5 2.5 Prototype V.1 and Testing Effects

3.0 FABRICATION 3.1 Fabrication Introduction 3.2 Design development and Fabrication of Prototype V.2 3.3 Design development and Fabrication of Prototype V.3 3.4 Final Prototype Development and Optimization 3.5 Final Digital Model 3.6 Fabrication Sequence 3.7 Assembly Drawing 3.8 Complete Sleeping Pod

4.0 REFLECTION

5.0 APPENDIX

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DESIGN OBJECTIVE

DESIGN BRIEF

KEY CONCEPTS

Design a sleeping pod for one person at university campus to provide user comfortable power nap without interference from surrounding environments

A three-dimensional wearable second skin that responses to the concept of personal space and its boundary with the environment.

VolumeMaterial systemPersonal SpaceSpatial and Emotional Ef-fectsRhino 3D modelling

0.0 INTRODUCTION

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title

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1.0 IDEATION

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1.1 OBJECT MEASUREMENT

TOP VIEW RIGHT VIEW LEFT VIEW

ISOMETRIC VIEW

The stool was physically measured by using scale rule and protractor. The top and two sides of the stool are traced on paper to draw the basic outline following the drawing of the croissants from Miralles & Pinos(1994).These measurements later are used to model the stool in Rhino by using InterpCrv, PlanarCrv, ExtrudeCrv command. Some parts such as side panels are mirrored by using Mirror command to boost the process. The plastic joints are modeled separately before being placed in the panels.

TOP VIEW RIGHT VIEW LEFT VIEW

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1.2 SYSTEM ANALYSIS

Theconvexsurfaceononepanelfitsperfectly with the concave surface on the other panel

Semi-circularplasticjointcreateaflexiblepin joints that allow rotational movement between panels

The most interesting mechanism of the stool is its folding transformation , which is based on the simultaneous horizontal and vertical movements of all 8 panels.

When a vertical force (Fv) or horizontal force (Fh) is applied onto the stool, panels 1 move horizontally in opposite directions, followed by the rotational movements of other panels.

The stool gradually transforms into its open condition with the side panels forming a strong scaffold that supports the surface above.

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1.3 Reconfiguration

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FRONT VIEW SIDE VIEW TOP VIEW

FRONT VIEW SIDE VIEW TOP VIEW

MAJOR DEVELOPMENT STAGES:1. The shape is created from applying the folding principles between panels of the stool.2. Length is added to increase the internal space and volume. Current shape appears to be quite dense3. Holes are added to reduce density of the shape

INSPIRATION:Mysketchmodelisprimarilyinspiredbytheimageofbutterfly’swings.Thesewingsareflatandtwo-dimensional but under different sources of light, it can create beautiful three-dimensional effects and the effects would change in different viewports and environment.Withitsflexibilityinshape,thesketchmodelhasthepotentialtobedevelopedintovariousdynamicstructure by combining them together in many different orientations.

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1.4 SKETCH DESIGN

DESIGN 1This design aims at creating protection around the right arm and chest area which is usually vulnerable to external attack

DESIGN 2Butterflyshapesindifferentscalecombinedtogether create an extended structure that provide protective shield around sensitive neck area and back, allowing user to lean on and have comfortable sleep.

DESIGN 3Spikychainofbutterflyshapeswrappingarounduser’sheadanduppershouldertoprevent attack and minimize interference from surrounding environment to the eyes, enabling a quality sleep

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Reflection from Module 1

The sketch model has great potential to develop into more dynamic and complex shapes.However, the three sketch designs appear to look similar to each other and do not have much distinctive features that create complexity and sophistication.

Also, folding mechanism needs to be analyzed and utilized moreefficientlyinthebutterflyshapesaswellashowtheywould be joined together.

Differentmaterialswillfurtherbetestedtofindthemostsuitable material for the structure as paper tends to dangle under self-weight, which is aesthetically unacceptable and hinders further development.

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2.0 DESIGN

Trinh PhamHenrik Green

Nik Lee

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2.1 Desgin Development Intro

ConsideringfeedbackfromModule1,wedecidedtofurtherdevelopthebutterflyshapes from Trinh and the leaf shape from Nik. Our initial design is a double-layer structure, in which the interior layer provides comfort for users while the exterior layer acts as a protection, preventing interference from surrounding environment.

Withitssharpandangledgeometry,thebutterflyshapesaresuitabletoformtheex-teriorlayer.Besides,theprofilingsurfaceoftheleafshapesprovidesperfectcomfortfor user.

WealsoworkedonnewsketchmodeltorefinethecurrentsketchmodelfromM1.

Protective exterior layer

Interior

Fabric layer

Interior

Plastic layer

RefinedSketchModel1

Module 1 Sketch Model

RefinedSketchModel2

Considering personal space, this sketch model appears to have much interior space and is vulnerable to external interference

RefineSketchModel1solvesproblemsofprivacybyaddingsurface, but later its density was not suitable for our design

Module 1 model was cut in halves and combined horizontally. However,thisnewsketchmodellimitsthejoiningflexibility.Intheend, we decided to revisited and further developed M1 model.

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2.1 Desgin Development Intro

Family, close friends

Acquaintances

Strangers

Asthebaseforourdesignprocess,model’spersonalspacewasmeasuredbyhavingoneperson changing distance from far to closer until she feels uncomfortable and each standing distance was recorded. It is noted that the model is highly sensitive around neck, chest and up-per arms area.

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2.2 Digitalization & Design Proposal V.1

TOP VIEW SIDE VIEW FRONT VIEW ISOMETRIC VIEW

Takingtheideaofflowersandbirdnest,thestructure considers the visual elements of a butterflyandleafsasapersonalsleepingpod.

The space gap between each panel also provides a peaking space for user, also allows lighttocomethrough,allowingasufficientamount of interaction with the surrounding world before sleeping

Space gap allows

peaking space

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2.3 Digitalization & Design Proposal V.2

ISOMETRIC VIEW SIDE VIEW TOP VIEW

Flat sheet with wave form Thin strips cut from the sheet The strips then arranged around the pod

Right elevation sketch with ribs

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2.4 Design Proposal V.3

Fabric & Metal frame

Foam or Fabric

should be soft and

flexibletosupportthe

neck

connected to hand

wrist

profilingcushionallows

movements of the

head

Unlike Proposal V,1, we aim at designing asleepingpodthatwrapsaroundone’sbody and can be attached to an existing chair

When user is sleeping, the external frame acts as a protection from surrounding environment. The upper part is enclosed in the spherical structure.

Folding movements of the external frame

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2.5 Precedent Research

Veasyble by GAIA California: Stage Set for John JasperseNot Whole Fence by Ball-Nogues

Visibility and light is controlled by altering the material density of the fence. This invites inter-action with surrounding environment.

Images from http://architizer.com/projects/not-whole-fence/ Images from http://www.veasyble.com/ Images from http://digit-all.net/California-Stage-Set-for-John-Jasperse

GAIA focuses on the concept of isolation and transformability by creating collapsible and portable device.

Translucent polycarbonate sheets can absorb and diffuse light, and they are connected by zip ties.

Polycarbonate sheets are potentially suitable for the panels in our design. Also, zip ties can also be solution for joining the panels together

The collapsible mechanism can be applied to our sleeping pod to enhance its portability andflexibility

Control of light, material density can be ad-justed to achieve comfortable quality of light inside the pod

APPLIED TO DESIGN APPLIED TO DESIGN APPLIED TO DESIGNAPPLIED TO DESIGN

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From precedent research, we examined thecollapsiblefunctionofGAIA’sback-pack to enhance the portability of current sleeping pod design.We also decided to use polypropylene as main material for the panels due to its translucencyandflexibility.Thetimberframehasbeenprofiledtofitperfectlytouser’sneckandbackarea, providing comfort and protection from behind.

TOP VIEW ISOMETRIC VIEWFRONT VIEW SIDE VIEW

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We tested out different joints including connecting the panels by using thread but it was too thin to resist the force.

We also tried zip ties but the ties were too big, making the system looks unaesthetic.

Wefinallycameupwiththepinjointsbetweenpanelsbycreating holes on one panel and arrow shape on another panels. This allows panels to join together without any ad-ditional joints

Different shapes were tested to im-prove the current panels

Curved system required many joints, whichreducetheflexibilityofthestructure

This structure has too much space and gap in between, which weeken the idea of privacy

Wefinallyrevisitedtheoriginalshapeand decided to further develop it

JOINTS

PANELS


ISOMETRIC VIEW

FRONT VIEW SIDE VIEW

TOP VIEW BACK VIEW


Translucent polyprolylence panels limit interaction with surrounding world but still allows light go through the pod and user to observe outside activities

Fastening details have been added to hold the panels in right position when the sleeping pod is used

Sharp edges of the polypropylene act as pro-tection and prevent interference

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2.8 Prototype V.1 & Testing Effect

SIDE VIEW

ISOMETRIC VIEW

BACK VIEW

2.8 Prototype V.1 & Testing Effect

Translucent polyprolylenc pan-els limit the observation from outside,makingtheuser’sfacegradually disappear into the white background. MDF frame withitsprofilingalsoefficientlyprotect user from behind.

Sharp edges at connection point created by arrow-hole joints between panels clearly definesone’spersonalspaceand acts as a warning to peo-ple who attempt to approach the sleeping pod

Folded condition of polypropylene panels Sharp edges at connection points

Side view of prototype V.1 Front view of prototype V.1

REFLECTION FROM MODULE 2

Module 2 marks the innovative combination between two different material systems, which arePanel&FoldandSection&Profile.Takingideas from precedent research , we created a foldable and portable system made out of polypropylene panels with arrow-hole joints that allow panels to be connected to each other without any additional joints. This system is sufficientlysupportedby3mmMDFframethatisbasedonSection&Profilesystemtoproviderigid protection and comfort.

Also, the design process is greatly aided by the use of Rhino through Paneling tools, Extruded-Crv, PlanarCrv, etc commands. Rhino plays a key role in providing a 3-dimensional represen-tationofourideasandefficientplatformtotestnew design.

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MOVING FORWARD MODULE 3

Prototype V,1 has series of problems that need to be further improved in next modules:- The prototype appears to be two systems joining together rather than one performing system.- Elastic characteristic of polypropylene make the panels dangle under self-weight and grav-ity force, which distorts the overall structure.- Considerable amount of force is required to compress and keep all panels in their folded position-Itisdifficulttocompressandkeepallpanelsin their folded position with current fastening details

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3.0 FABRICATION

Trinh PhamHenrik Green

Nik Lee

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3.1 Fabrication Introduction

Taking feedback from Module 2, there are several key concepts that need to be tested and developed:

Thepanelsappeartobeflatthatdoes not create much space and volume, thus resulting in two-dimensional appearance of the structure. Our solution is to further develop the panels into a three-dimen-sional shape but keeping the overall outline as we are happy with the arrangement of all panels.

The initial folding function seems to hinder further design development, so elimination will be considered.With the consideration of elimi-nating folding function, MDF frame will be redesigned to better support the panels and to solve the problem of having two seperate system joining together.

Site is taken into consideration. We chose the long bench in the atrium in Melbourne School of Design as location for our sleep-ing pod.

Frequent movements and activities including walking, eating, running are observed throughout the day. Therefore, our aim is to create aportableandflexiblesleep-ing pod that does not take up much space or hinder move-ments

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3.2 Design Development & Fabrication of prototype V.2

Double layers add volume and space

to the structure

Top view showing internal round layer

and sharp external layer

Outline of personal space

In order to increase volume, we considered having two layers: a round internal layers to create comfort and a sharp external layer to clearly definepersonalspaceandsetbarriersbetweenuserandsurroundingenvironment

Having eliminated the folding function, a new frame was designed to provide lateral support to the panels. Unlike the rigid geometry of the panels,theframewasdesignedinfreeformtoenhanceitsflexibilityandinteresting look.

Folding the panels in two different directions

increases internal volume

Red area shows the space created by join-

ing two panels together to form outer layer

The connection points of two panels

create a sharp structure that clearly

definepersonalspace

Top view of panels

Inner layer

Series of shapes were tested and new panel with greater volume was created by folding different parts of panels in opposite direction

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3.2 Design Development & Fabrication of Prototype V.2

ISOMETRIC VIEW

FRONT VIEW SIDE VIEW

TOP VIEW

Double panels joints on

front side provide higher

protection to sensitive

area (chest and face).

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FRONT VIEW

Sleeping pod tested on site Side view of prototype V.2

Prototype V.2 solved the problem of having two separate systems joined together by placing polypropylene panels in three rolls around the new MDF frame. With its translucency, the panels soften and blur out the frame as if it has been disappeared into background. The panels also perform as semi-invisible barrier as expected.Theouterprofilingedgeoftheframewellfitswiththebench.How-ever, the lower part of inner edge curving inward creates discomfort to the back of user.


SIDE VIEW ISOMETRIC VIEW

BACK VIEW

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In prototype V.3, rounded edges of MDF frame has been changed to angled edges.The lower part of the innner edge has been shortened to solve the problem of discomfort in prototype V.2Also, the the holes in the frame have been extended to allow two panels join-ing simutaneously.

When tested on site, Prototype V.3 showed desired effects, particularly the blurry, fading from polypropylene panels and angled supporting frame that makes the structure now looks like one perform-ing system.

Extended holes for double-panel joints Rhino model and angled frame

Sleeping pod tested on site: Side view Sleeping pod tested on site: Front view

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3.4 Final Prototype Development & Optimisation

EFFECTS

FABRICATION

Curved frame was changed to angled frame to propose similar system with the panels.However, the internal edges remains rounded to ensure enough comfort to user

The orientation of the pan-els in internal layer were changed while the panels in externallayerwereflippedtoshow the sharp edges

Internal layer External layer

In prototype V.2, MDF got thinner after laser cut and led to breaking of the frame at the notches.This issue has been resolved in Prototype V.3 by making the frame wider at important notches

Prototype V.2 Prototype V.3

Use Gumball to slight the pieces apart

before creating the notches

After notches created, the pieces are

moved apart sing Gumball

ThepieceisplacedflatbyOrient3Pt

Notches are created by using using

Boolean2Objects

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MATERIAL USAGE

We tried spray painting the MDF frame and it looks good on surface. Yet, the smell might negatively affect user

New material - bamboo plywood has been used in replacement of MDF as its texture looks moreinterestingthethecolorfitwiththetranslu-cent panels

We tried sanding the burnt edges of bamboo after laser cut but it does not look as good. We decided to leave the edge in dark color.

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MATERIAL USAGE

The frame and panels are placed in 600x900mm and 600x600 sheets for cutting. They are arranged closely to each other to take up less space, thus saving cutting cose

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3.5 Final Digital Model

ISOMETRIC VIEW

TOP VIEW

FRONT VIEW

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3.6 Fabrication Sequence

Step 1: Sanding bamboo to remove brunt marks on surface

Step 2:Attach vertical and horizontal part of the back frame together

Step 2.1: Put three members of the back frame together

Step 3: Insert balsa wood into the gap between bambooframetofillupthegap.Thisgapwasresulted from the inconsistency in thickness of bamboo after laser cut.

Step 4: Continue adding additional vertical ele-ments on the sides and in front to the frame

Complete frame

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3.6 Fabrication Sequence

Step 5: Trim abundant balsa pieces off the frame for aesthetic purpose

Step 6: Fold all laser cut panels and put them in different catergories for easy assembly later

Step 7: Start placing panels for inner layer from the front left

Step 7.1: Continue arranging inner layers from front to the two side. Cut off some part of the arrowstobetterfitwiththeframe

Step 7.2: Connect second layer of panels after finishingtheinnerlayer

Final touch to make sure all panels placed in right positions

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3.7 Assembly Drawing

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The number labels indicate the order of assembly process. Pieces with similar numbers have to be constructed and held simulta-neously in order connect with the next pieces. Serious attention should be paid to the notching connections as wrong assembly order might result in breaking the notches.Blue code indicates vertical pieces, while pink code indicates horizontal piecesBalsa wood packing might be needed at some notches to tighten the connection.

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3.7 Assembly Drawing

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2The number labels indicate different type of panels that needs to be put in correct position.Color code shows the order of assembly process. Green pieces are panels in internal layer and have tobeassemblefirst.Redtodarkbrownpiecesareinexternal layer.

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3.8 Complete Sleeping Pod

FRONT VIEW

SIDE VIEW

BACK VIEW

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Connection between two panels in the outer layer create sharp points, which act as a physical protection for user and a warning to people who are approaching too close to the sleeping pod.Translucent characteristic of the panels also create the fading effect, as if the sleeping pod is disappearing into background.

Arrow joints are not only used for connecting panels together but also for connecting panels with bamboo frame based on the same principle

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FRONT VIEW SIDE VIEW BACK VIEW

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FRONT VIEWA clear boundary set between user and sur-rounding environment

SIDE VIEWThe sleeping pod gradually disappear into back-ground due to the translucency of the panels

SIDE VIEWBamboo frame rest on the bench and support the neck and body.

SLEEPING POD ON SITE

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EFFECTS

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REFLECTION FROM MODULE 3

Module 3 has proposed one of the most interesting aspect of Design and Fabrication process, which is how digital and physical model and the fabrication techniques can have great impact on the design and some-times change the initial ideas. From week 6 readings, Kolarevic (2003, p.35-39) introduces different fabrication techniques including two-dimensional fabrication , subtractive fabrication and formative fabrication. This has broaden our understanding of great availability of techniques and how our ideas would not be limited by the lack of technol-ogy.

One challenge was that bamboo plywood after laser cut would sometimes have its thickness altered by 0.5mm. This small change in fact had a huge impact on our frame model.The5mmnotchesarenolongerfitwith each other, thus weakening the whole structure. We had to used balsa to solve the problem and extra care was taken.

In addition, reading from Iwamoto (2009) on folding aspect has also helped us better un-derstand the folding techniques and how to develop complicated structure from simple and geometric shapes. We applied these ideas into creating 3D panels by folding them in opposite directions.

Tosuccessfulproducethefinalproduct,wehave been greatly aided by the help of fab-rication techniques, physical model, and 3D modelling tools such as Rhino.

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4.0 REFLECTION

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4.0 Reflection

Throughout three months of designing and fabricating a complete sleeping pod, there have been numbers of interesting concepts raised in each module and challenges that I and my team had to face in order to move forward.Module1guidedmethroughtheprocessofcloselyanalyzinganobjectanddesigningarefinedsketchmodelbased on the physical characteristics and mechanism of the object. I was greatly amazed by the number of rulesandprinciplesIcoulddrawfromasimplestooltodevelopmyownmodels.OneoftheveryfirstchallengesthatIfacedinthismodulewastocomeupwitharefineddesignfromtheobject.Myideaswerelockedintoaninvisible frame as I did not have a holistic approach from different angles and scale to fully explore the potential of my sketch model. Consequently, all my sketch designs bear many similarities to each other and did not really response to the concept of personal space.Moving to Module 2, with the sharing of different ideas and designs from teammates, we came up with more sophisticated design that well responses to the main themes in the module. Rhino 3D modelling became an incredibly helpful tool to visually represent our idea and explore other potentials of the design. However, some-times the lack of software skills might hinder the design process and did not allow us to fully represent our ideas. I also found this module the most challenging of all three because we had been moving back and forth with our design ideas many times and were completely stuck at some points. From this I have learnt an important lesson that a design is only successful when it has been tested in reality. Also, critical feedback and peer review play animportantroleindevelopingandrefiningourmodel.

The fabrication process in Module 3 helped me explore how physical/digital model and fabrication techniques canhavesignificantinfluenceondesignprocess.LasercutenablesmetoexplorewiderrangeofmaterialssuchasMDF,bambooandpolypropyleneandunderstandtheirbehaviors.However,attimesconflictsalsooccurredthat can dramatically change our design. We initially wanted to have a foldable sleeping pod based on folding mechanism. However, after laser cut the polypropylene panels and joined them together, we realized that due tothecharacteristicsofthematerial,itisdifficulttocompressandkeepallpanelsinrightpositionwithoutcon-siderable amount of force. Testing our ideas on physical model has helped us quickly understand the problem and come up with better solution.

Overall, we successfully produced a complete sleeping pod with through different critical process including 3D modelling, subtractive fabrication, prototype and peer-reviewed feedback. Considering the concepts of democratization of energy and technology raised in the reading of Rifkin and Macmillan (2011) and this sleep-ing pod design, it is noted that we are living in the era where everyone is given enough tools and technology to make their own product and become manufacturers. With the help of 3D modelling, printing and advanced fabrication techniques, we can better visualize the world and go beyond the boundaries that old worlds have set.

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5.0 Appendix

Bibliography

Ammar Eloueni Digit-all Studio, California: Stage Set for John Japserse, viewed 05/06/2016, < http://digit-all.net/California-Stage-Set-for-John-Jasperse>

Enric, M, Carme, P 1988/1991, How to lay out a croissant, El Croquis 49/50 Enric Miralles, Carme Pinos, En Construction, pp.240-241

Iwamoto, L 2009, Digital Fabrications: Architectural and Material Techniques, Princeton Architectural Press, New York

Kolarevic, B 2003, Architecture in Digital Age – Design and Manufacturing, Spon Press, London

Rifkin, J 2011, The Third Industrial Revolution, Palgrave Macmillan, p.107-126.

Yatzerland Ltd 2007, Veasyble by GAIA, viewed 06/06/2016, < https://www.yatzer.com/Veasyble-by-GAIA>

IMAGES REFERENCE

“California: Stage Set for John Jasperse”, viewed 05/06, < http://digit-all.net/California-Stage-Set-for-John-Jasperse>

“Not Whole Fence”, viewed 05/06, < http://architizer.com/projects/not-whole-fence>

“Veasyble”, viewed 05/06, < http://www.veasyble.com/>

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5.2 Credits

Page Drawings Computation Model Fabrication Model Assembly Photography Writing Graphic Design Page Drawings Computation Model Fabrication Model Assembly Photography Writing Graphic DesignCover rrr r Cover r6 rrr r r r7 r 52 r r

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TRINH PHAM

HENRIK GREEN

NIK LEE

CREDITS

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