Scale Project:
This page will aim to document and display my design making process for the scale project (Assignment 2 P1).
Initial Ideas:
When starting this project, I was a little blocked as to what object to pursue that would be both 'makeable' and display high levels of craft through complexity. With this brief in mind, I managed to narrow down my possible objects to 4. These would have varying degrees of difficulty, but allowed me to decide upon potential plans to take towards the making process.
Chosen Object:
As a result of this initial research I decided upon the chess pawn as the object I would pursue with this project development. I believe this object has a high degree of complexity, especially when considering the net that will be required to produce this piece, and the inclusion of many curves. With this project, I aim to test what I can complete in a 9 day period, and with previous projects I have completed favoring geometric shapes, I decided to pursue a circular object.
Initial Drawing:
Initial CAD modelling:
After deciding upon the object, it was then time to complete the first stage of the modelling development. This being converting my physical object into something in CAD software, my chosen application, Fusion 360, (although this would ultimately change to Rhino as the project progressed). Through this process I aim to develop a 3D CAD that can be easily converted to other CAD software, whilst also displaying all the key elements of the design. First, I measured the elements of the piece with a Vernier caliper.
The above images display my CAD process in Fusion. I initially started with developing a 2D interpretation of my object. This displayed the dimension (45mm,23mm) of a cross section of the object. From this I developed a 3D model using the Revolve tool, which produced an accurate model, but with a limited amount of detail. However, the main issue with developing this model was the doubly curved surface, which could not be used to produce a net in Rhino. So for my next CAD model, I decided to address this.
To develop greater detail, and to eliminate the doubly curved surface, I decided to create a new model, which included greater attention towards the sanded (soft) edges of the original piece, and made the top out of multiple panels to eliminate the error, allowing the design to be printed on Rhino. (Although issues would be run into, which you will soon find out about).
Craft Tutorial:
An important part of this project is craft, which we explored through a tutorial. These images display the object I created through this process. I learnt the importance of planning, as the inclusion of a thoroughly developed net speeds up the production process.
Unwrapping Project In Rhino:
Due to unique features, unwrapping a object to form a 2D net becomes very simple thanks to the 'unroll' tool. However the first major hiccup that I experienced was when unrolling the developed Fusion model in Rhino. Due to the many elements that were required to create the curved edges, it produced numerous small elements which would be very difficult to produce to a high level of craft. As seen below:
This presented a issue, as I was already time constrained. The amount of time that would have been required to develop this model to a suitable level of craft would have been more than the amount I had at my disposal. Therefore the decision was made to simplify the object on the Rhino application, (as by this time I had become familiar with the software).
Scale:
As this project specifies that the object must be scaled up to fit within a 400x400mm cube, I scaled a model up to identify the scale factor required to fulfill this requirement. (Through the use of a bit of math's) I identified that a scale factor of 8.7 was required. below is the investigation work I did, with the initial and final, (scaled up model), side by side.
Final CAD Model:
For my final CAD model, my hand was forced. Therefore, due to time constraints, I decided to simplify the model and include knowledge gained through the initial models, notably the inclusion of multiple panels to form the ball at the top. With the scale factor known, I was able to create a initial net for my model which I could use to develop a prototype.
Initial Prototype:
After printing out my net in 4 distinct A3 sheets, it was time to construct the prototype. The images below displays the process, where I had to cut tabs, and the panels themselves, and construct the prototype using A3 paper.
The bottom right image displays the completed prototype, which I was overall pleased with. Although the level of craft likely could have been improved had more time been allocated to construction, this prototype ultimately fulfilled its purpose. That being an aesthetic model, which would display the proportions and look of the project through a tangible medium. As this was a complete, scaled up prototype, it gave me a run-through of the construction methods and techniques required to complete the final model.
Reflection on Prototype:
I was happy with this model as it completed the brief I had set out for this particular model. I also learnt the importance of effective tabs, and the difficulty of access for them in this model. However, it would have been better if I had modelled using a more representative material, i.e. card, as this could have better prepared me for how to work effectively with the material we would use in the final model.
Final Model:
After completing my prototype, there were definitely a few takeaways. These being, 1) The importance of planned and effective tabs, 2) The difficultly of access to particular panels whilst constructing, and 3) Tape can be used as effective adhesive solution, as opposed to using glue for everything.
The first plan of action for my final model was developing a better net with developed tabs. This included below:
After printing out this file, it then came to cutting and construction. This is where the learnings of the prototype became useful, as (for example) tape became a time-saving tool (especially useful where you are time constrained). Below displays my process of making:
Final Model (Completed):
Note: Above include a comparison between prototype and final model.
Reflection:
Overall, I am very pleased with the result of this project. As I initial set out to challenge myself to get more familiar with creating curves and circular objects, the level of craft may not have been the same as if I had created a geometric object, but I believe the personal development I experienced as a result of this was worth the trade off. I am also proud of the development between my final and prototype models, even given the limited time in-between the construction of them.
One of the main limitations I had to work within was a lack of time management. As I had failed to properly identify the time required to complete the modelling section of this project, it meant that for most of the construction phase I was time pressured, which may have hampered my overall level of craft.
The main takeaway I will use in the next projects will be a better use of planning. A lack of developed parts of the designing phase lead to disruption further into the development of the model, and ultimately slowed my progress. I believe that if I spend a little more time being careful and precise in the planning phase, I will improve my time management and end up with a better model at the end.
