tupa idea book / 2011
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tupafinland.comTRANSCRIPT
Developing Tupa:
Prototyping Collection
Introduction
The 2010-2011 academic year marked the beginning of an exciting relationship
between UPM, Aalto University in Finland and the Kyoto Institute of Technology in
Japan through a course called Mechanical Engineering 310, or ME310 for short. A
Master’s level course that brings students through each step of the product
development process, the ME310 experience is enriched through partnerships with
world-class corporate sponsors, such as UPM. Working with UPM’s new Grada™
Plywood, our team was tasked with creating a new product using this material,
targeted speci�cally at the packaging and casing industries.
This book captures many of our key prototypes and favorite ideas from the year.
This progression of work eventually culminated in the development of our �nal
prototype, the Tupa Maternity Package, which made its global debut at Stanford
University’s 2011 Design EXPE on June 2nd, 2011. As the course was split up into
three periods — fall, winter and spring — this book is organized according to this
same chronology.
Enjoy!
- The UPMxME310 Team
FALL PERIOD: OCTOBER-DECEMBER 2010
Plyphone
Softwood
Glowing Wood
Magnet
Plyphone
As our team’s �rst prototype, the Plyphone helped us to understand how plywood
behaves as a casing material. By testing the achievable bending radii with the
plywood, that may have dictated size of product casings we could build. Via
in-person interviews, with Plyphone we could also test user impressions about
combining wood with other materials like metal and plastic. The plywood used we
made ourselves out of three layers of 0.8mm birch veneer and common wood glue.
Softwood
What if wood were soft? By carefully slicing thin sheets of veneer and taping them
to a cushioned material with double-sided tape, we actually made wood soft. Feel
it, scrunch it, or squeeze it, softwood appeals to our desires for materials that are
anything but hard and cold.
Glowing Wood
Featuring a dynamic Electroluminescent (EL) sheet, this concept demonstrates the
brilliant effect that comes with combining wood and light together. In some places
the wood is thin enough to let the light shine through, with other cut shapes made
into the surface to allow full light penetration. As wood and lighting are vital
components in interior design, with this execution the wood appears to be
producing light independently.
Magnet
With the increased bendability of the plywood, magnets proved to be an effective
way to snap-�t sections together, or make closed shapes. The Neodynium magnet
used here is extremely strong and when placed underneath a layer of veneer,
creates a seamless and elegant connection mechanism.
WINTER PERIOD: JANUARY-MARCH 2011
PaperBot: The Angry Frenchman
Plycycle
Plydimensional
Without An Oven (WAO) Ply
Plycar
The PlyFit Process
Sports Wheelchairs + the Univehicle
PaperBot: The Angry Frenchman
Our PaperBot, the Angry Frenchman, gently plays off of some quintessentially
French traditions. The intent of the course’s PaperBot assignment was to encourage
us to work with electronics, and to build con�dence in our team to incorporate them
into our future prototypes, if needed. The key action performed by the Angry
Frenchman was to angrily tilt his eyebrows when his baguette was removed, charge
ahead and spray silly string upon identifying a target.
Plycycle production process
4 bend3 push 5 assemble2 heat1 plywood
Plycycle
Perhaps a wooden bicycle isn’t exactly something new, but this one took us about
two hours to design, bend and assemble. With a plywood frame that can be bent to
match any rider’s dimensions, the curved pieces also act as support and
suspension for the rider. And with no formaldehyde in UPM Grada Plywood it makes
for an ideal children’s toy as well. This simply but sturdily built prototype also
demonstrates the plywood’s exceptional strength-to-weight ratio.
Plydimensional
We found that three-dimensional shapes (bending across or perpendicular to the
grain direction) were hard to achieve with the material, so we developed
Plydimensional to help overcome this hurdle. This prototype works by scoring or
cutting the layers of veneer to allow them to move and bend with more freedom.
Either an intact veneer layer or the glue layer helps to keep the panel from falling
apart completely. With this technique we could test making enclosed shapes
further.
Without An Oven (WAO) Ply
As achieving the plywood’s bending temperature outside of an oven or hot press
offered many design possibilities, WAO (Without An Oven) Ply was an exciting
prototype. Rows of resistance wires were strung across the top of one plywood
panel and sandwiched between another panel. When an electric current was
applied, the heat generated successfully brought the panel to the 130ºC bending
temperature.
WAO production process
Plycar
UPM Grada Plywood boasts a compelling strength-to-weight ratio and the
transportation/car industry is seeking solutions to make lighter yet stiffer
constructions. As Plycar is a partial car interior made from plywood, it helps to
explore the opportunities in this lucrative market while also revealing wood’s visual,
tactile and retro-style appeal. However, distinct challenges to the concept lie with
safety regulations and the closed nature of the car design industry.
110℃-130℃ Fitting machine Simply Powerful
The PlyFit Process
While investigating custom-�t seating solutions for sports wheelchairs, we designed
a quick and simple process for creating precisely �t custom shapes. The PlyFit
process follows these steps:
Step 1: insert room temperature, �at, cut plywood form into preheated oven at
130℃. Plywood should reach 130℃ after about 10-15 minutes.
Step 2: carefully remove heated plywood and place onto “�tting machine”.
Step 3: protecting your body from the heat, use your body as a mold and sit onto
the heated plywood atop the �tting machine.
Step 4: remain in place on the �tting machine for 4-5 minutes. Then, remove your
custom-�t plywood seat from the �tting machine.
Sports Wheelchairs + the Univehicle
Wheelchairs, and sports wheelchairs in particular, are expensive to buy and the
seats especially require precise �tting to the user. However, through the PlyFit
Process developed by our team even casual athletes that are disabled can still own
a high-performance, custom-�t wheelchair seat made to their dimensions easily and
quickly. Only through the production ef�ciencies of UPM Grada Plywood can these
products become more affordable and more accessible to users.
Univehicle: Developed by GK Kyoto Inc. in Japan, the
Univehicle is just one example of an immediate
application of the PlyFit Process in the market.
SPRING PERIOD: APRIL-JUNE 2011
Shoebox/Shoe Stand
Hard + Soft
Shoebox/Shoe Stand: The Second Meaning of Packaging
In most cases a product’s packing is just a lifeless vessel that protects a product
while being shipped or is used to advertise it. But can a package do more? To
probe this question further we created a plywood shoebox that can also be turned
into a shoe stand, quickly and easily. The more shoeboxes you buy the larger the
shoe stand can become, creating a stylish yet functional piece of design for any
home. Plus, by designing packaging to be more multi-functional we are saving
space and eliminating waste at the same time, too.
Hard + Soft
This idea shows the potential of combining the strength and formability of UPM
Grada Plywood with the �exibility and expandability that only fabric can provide.
Also, fabric adds a lot of opportunity to bring more color and �air into any design.
Especially for gifts, a combination of hard and soft can make traditional gift
packaging even more dynamic and special for the recipient.
Developing Our Final Prototype
The Tupa Maternity Package
As with all of our other prototypes, the development of
our �nal Tupa prototype was a separate journey in and
of itself. These next pages demonstrate the steps we
took before arriving at our �nal design for Tupa that
debuted at the Stanford University Design EXPE on
June 2nd, 2011.
use curved shape for rocking
how to get stable structures
multi-functional
cylinder
long life product
focus on the U-shape
functional study
we meet ‘house’ shape
TUPA BOX
Box Rocking Bed Rocking Toy
Table + Chair
Rocking
Used in our online survey, this version �rst began to explore a rocking motion in the
crib. This was a popular feature as rocking helps to calm babies and put them to
sleep.
Feeding Chair
Our �rst attempt at creating a feeding chair, this design brings the baby to the same
level as the adults at the dining table. The large dimensions of the Maternity Package
made the design feasible, but we struggled to achieve one that looked sturdy
enough to get mothers comfortable with sitting their babies down.
U-shapes
This drawing began to introduce the u-shape (�oating shapes on top) that sits into a
large, single shaped lower body. This design was also unique in that it is
expandable, where the slots in the bottom section allowing the box to expand and
retract to serve in different functions.
Rounded Design
The most rounded of our concepts, this cylinder shape is approachable in its
design, and functional in that it creates several stools or tabletops for use in different
situations. We did not pursue this design long enough to solve its possible fondness
to roll away, however.
Multi-functionality
At this stage we really felt comfortable with the level of multi-functionality we were
delivering. This concept clearly acted as a box for storage, but also came apart to
act as stepping stool and chairs — functions that are present in Tupa today.
Five Pieces
Made up of just �ve core pieces, this design shows a more simplistic and elegant
take on the u-shape idea.
Adjustability
A departure from our simplistic tendencies, the high number of slits and cuts made
this look too complicated to use, and would certainly have been too challenging to
fabricate. However it showed promise in its adjustability.
The House Box
Already showing obvious signs of Tupa, this prototype we �nally named, and we
named it the “house box” as it looks so much like a house or barn. It consists of a
large top cover that overlaps a bottom cover, and also introduces additional coloring
on the end cap pieces.
Finally: Tupa Is Here!
Tupa, meaning “great room” in Finnish, is the revolutionary new design for the
Maternity Package made from UPM Grada Plywood. In Finland every expectant
mother receives a Maternity Package that contains many of the essentials for a
baby’s �rst year of life. Even the box is often used as a �rst bed. More
multi-functional, stronger and more stylish than the original, Tupa adds the
functionality of a rocking crib, table and chairs and even a toy box. Tupa is truly life’s
most precious package.
Thank You!
Haruna Kawashima
Heikki Soininen
Julia Pettersson Hakava
Kento Misawa
Mamiko Nagao
Paul Warrunthorn Kittiwongsunthorn
Rumi Yoshida
Tuomas Sahramaa