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

Trinh Pham, Nik Lee, Henrik Green(784173, 697421, 803461) Joshua Russo - Tutorial 7

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Introduction

From M2, there are specific problems that need to be resolved. First, the panels appear to be quite flat (two dimen-tional) and does not create much space. Also, without lateral support, the panels dangel, which is not aesthetically acceptable. The folding function has not allowed us to fully embrace the potentially of the design. Serious consider-ation of eliminating this element is needed.On the other hand, the MDF frame does not efficiently support the panels, and is only connected at two ends. This leaves an impression of two systems being joined together, rather than one performing system.Therefore, we aim to redesign the the MDF frame by adding more horizontal and vertical strips. We also plan to cre-ate new panels by adding more depth and space to them.

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Design development

In order to create volume for the sleeping pod, we considered having two layers of panels. A rounded in-ner layer is added to create comfort for the user and a sharp outer layer to visually communicate a need for privacy. The layers should be set apart to reproduce the outline of one’s personal space.

Volume is created by adding layers to the

previous design

Top view showing two different layers Outline of personal space

The folding panel in thre previous design create too many constraints to further development. Therefore, this feature was dropped and a new frame created to better support the panels and allow multiple layers.As the panels have rigid geometric shape, we wanted to desig the frame with more flexibility and thus, had them in more free form shapes.

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Design development

We tested out series of different shapes to create more volume and space

Two shapes in M2 were joined together. However, the joints reduce the flexibility of the panels, and it appears to be two seperate forms being connected.

New shapes were created by cutting and folding the panels in two ways

Depth and volume significantly increase in the new shape

by folding the panel in two opposite ways

Inner layer

Surrounding Environment

The connection point of two panel

create a sharp structure which

clearly show one’s personal space

Red area shows the space and volume created

when joining two panels together to form the

outer layer

Top view of the

panels

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We chose the long bench in the atrium in MSD as the specific location for our sleeping pod. The bench is located in an open space with many tables and other benches. It was also observed that there are different movements includ-ing people walking, studying, and talking in the area. Therefore, the design of sleeping pod should not take up too much space and should be portable and flexible to minimize the interference with other activities.

Site Analysis

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Design development + fabrication of Prototype V.2

Prototype tested on siteFRONT VIEW

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TOP VIEW

SIDE VIEW ISOMETRIC VIEW

Rhino model of refined design

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Architecture 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?

Reading Response Wk 6

Digital fabrication processes include two-dimensional fabrication, subtractive fabri-cation, and additive fabrication. Two-dimensional fabrication uses different cutting technologies such as laser-beam, water-jet and plasma-arc and is based on the basics of high pressure and intensity. Subtractive fabrication removes volume of a material by milling process. One of its technology is CNC multi-axis milling. Additive fabrication, on the other hand, involves the process of adding more volume to existing materials, often refering as “layered manufacturing” or “rapid prototype”. 3D printing and Selec-tive Laser Sintering are examples of additive fabrication.

In the processing of making the sleeping pod, we had MDF and polypropylene sheets laser cut to test out the joints and structure. If problems occur, we would revisit our design and change it.

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Reading applied to design

How does the fabrication process and strategy effect your second skin project?

Fabrication process, especially laser cutting directly effect our choice of materials for the sleeping pod. It enables us to test out on wide range ma-terials that are difficult to cut and fold by hand such as MDF, bambo, and polypropylene. The accuracy of the cutting process allows cutting of complex geomeotry and fine details such as the slots for the panels. Also, since it is a digital pro-cess , it allows direct translation between the curves in the Rhino software into physical material. However, it also raises many problems regarding burnt marks, water frost on materials that we had to revisit and change our sketch design. We initially planned to use MDF as materials timber frame. However, after laser cutting bamboo strips, we found out that bamboo frame has more aesthethic per-formance. Also, the burnt marks on bamboo frame can be sanded away by using sanding paper, while it is difficult to treat the burnt marks unless the frame is painted.

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Digital Fabrications: architectural + material techniques/Lisa Iwamoto. New York: Princeton Architectural Press c2009

Describe one aspect of the recent shift in the use of digital technology from design to fabrication?

Reading Response Wk 7

Folding is one of the aspect of recent shift in the use of digital technology from design to fabrication. It is the method that turns flat surfaces into a three-dimensional surfac-es. There have been arguments that the method of merely folding a surface could not create any structure with complexity and sophistication. However, it has produced numbers of iconic structures that partly shaped the contemporary architecture. Fold-ing is economical in materials usage, visually appealing and can works well regard-less of project scales. By deforming and inflecting, folding can create different three-dimensional surfaces, and it has the potential to manisfest a wide range of forms.

Through folding in dffierent direction, , more volume and space were added to the panels, creating a 3-dimensional void space

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Reading applied to design

Referencing from the lectures and readings, what is the implication of digital fabrication on your design ?

Folding’s long history in craft-based practices and product design has influenced shaped the aesthetics of contemporary architecture. From the reading, we wish to apply to our current design by expanding our panels from a 2 dimensional form to a volumed space. It is apparent to us that by stretching the space on the y axis and maintaining the geometric position of the x points , void spaces are gener-ated. Using the folding technology, we are given the opportunity to create ma-terial density and complex geometric systems by adjusting different void spaces.

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Prototype development

The previous shape of the MDF back strips creates discomfort to the back of the user when she was using the sleeping pod. Our solution was to shorten the lower extensions of the 3 back strips and smoothen the edges so that it would support the back without causing any pain.

We made the holes connecting the panels to the frame slightly big-ger that two panels can fit in. This allows panels to be connected from two different directions.

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Prototype V.3

Elevation of Prototype 3

Details showing the connection between polypropylene panels

Rectangular holes were cut on the MDF frame to connect the panels

Testing the sleeping pod on site.

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Prototype optimisation

As the structure appears to be two systems connecting to each other , we decided to replace the curved frame with the ange-led frame. The new frame still has profiliing curves inside, but the outer edges are designed to be angeled, which is similar to the shape of the panels.

We changed the orientation of the panels on the inner layers to produce more curved shapes. On the other hand, the outer layer, the panels are flipped and connected to create a sharp edges, setting clear barrier be-tween user and environment.

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Translucent polypropylene panels create a partly invisible boundary between user and surround-ing environment. The sharp edges of the timber frame and at the connections of the panels acts as protection and give the sense of danger to people around the area. The rigid MDF frame sup-ports the panels and create a clear barrier of user’s personal space

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Prototype optimisation

In prototype 2, the frame was broken at the notches because the MDF got too thin after laser cut

In Prototype 3, this issue was solved by making the frame wider at critical notches

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Using Gumballl to the pieces slight apart be-fore creating the notches

Notches are created by using Boolean2Ob-jects

After the notches are created, the pieces are moved apart using Gumball

The pieces are placed flat by using Orient3Pt The cutting files produced by using Make2D

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Prototype optimisation

We tried spraying primer and white paint on the MDF frame. The paint iwas evenly distrib-uted on the flat surface, but the edge did not look as good. Also the smell of the spray-painted frame might negatively affect user

We came up with a solution, which is using bamboo plywood in replacement to MDF. The texture is more interesting and the light colour well fits with the translucent panels

The edge of the bamboo frame got burned after laster cut. We tried sanding, but it does not look aesthetic. Therefore, we decided to only sand the flat surface and leave the edge in dark color.

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The pieces for the frame were placed onto a 600x600 cut-ting sheets to save materials and material cost

The panels are placed on 600x900 sheets with clear labels so that it would be easy for fabrication. They are also nested close to each other to save materials.

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Final design

ISOMETRIC VIEWFRONT VIEW

TOP VIEW

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Rhino paneling tool issue

We tried using paneling tools for the panels, and found it slightly difficult to place the panels in the positions that we wanted. However, the paneling tools work well with the inner layer, so our solution was to do paneling tools for the inner layer and manually place the outer layer on top.

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Fabrication Sequence

1. Sanding bamboo to remove burnt marks 2. Assembly starts at the back of the frame 3. Back and horizontal strips glued together

4. Inserting balsa pieces to fill the gap between bamboo elements as the material thickness is not constant

5. Additional vertical elements on the sides added to the frame

6. Complete frame

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7. Trimming balsa pieces 8. Folding of polypropylene panels 9. Panels attached to frame starting from inner layer

10. Adjusting the panels to have them joined perfectly with the frame

11. Finishing the inner layer 12. The outer layer is added to the frame

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Assembly Drawing

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2nd Skin

FRONT VIEW

SIDE VIEW BACK VIEW

Connection between two panels in the outer layer create sharp points, which act as a physical pro-tection for user and a warning to people who are approaching to close to the sleeping pod

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Polypropylene panels arranged in two layers prevent people from outside to look through the sleeping pod, but still allow users to oberve most activities in the surrounding environment. Also the sharp edges at the connection point between two panels clearly determine user’s personal space and gives an impression of danger to thotse who attempt to approach. The bamboo frame acts a rigid structure to support the panels and set a visible barrier between one’s personal space and the environment.

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FRONT VIEW OF SLEEPING PODFrom front viewport, especially on black back-ground, the sleeping pod set a clear boundary between users and other people. Not only the head but shoulder and lower part is protected

SIDE VIEW OF SLEEPING PODFrom side viewport, the sleeping pod looks slightly transparent and disappear into the back-ground. This provides minimum interferene with other activity and does not distraction to other people

SLEEPING POD IN USEThe back frame resting on the bench and the wall well support the neck and body, providing comfort for user

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We put a light inside the sleeping pod to test out light distribution. Double-layered panels diffuse the light and allow some to go through the sleeping pod. This creates some 3-dimentional effects and provide comfort to user’s eyes without being annoyed by too much light in the atrium in Melbourne Shocl of Design