dim. by Nicola Liston S3377561
TASK: Create something that is achievable in 12 weeks “and on the 8th day, Scott and Nigel created....” Define achievable...
my head hurts already
3D printing Genesis chapter I
“Oh and buy a printer... you could probably do it for $400” -Scott Mayson “no you can’t....” -Nigel Brockbank
I’m not sure of what lies ahead....
“If you’re not prepared to be wrong, you will never come up with anything original” -Ken Robinson
but I suppose it’s quote worthy...
1) http://i668.photobucket.com/albums/vv42/amd1013/916b8035.jpg
INSPIRATION: Mechanisms To find inspiration I looked away from existing speakers but to interesting mechanical components that really changed how objects were traditionally operated. This revealed that real opportunity could be found in seemingly mundane of objects
Bag holders, Effective use of material and distribution of weight. thorough understanding of weight bearing tolerances.
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1) Berocca twist tops highligted the appropriate use of materials and efficiency and innovation in a product
1) http://i668.photobucket.com/albums/vv42/amd1013/916b8035. jpg 2)http://www.invetech.com.au/img/showcase/showcase-berocca-2.jpg
INSPIRATION: Forms The overall form of something holds the key to the design. Aesthetically if the form isn’t right the object may not be picked up or used (particularly at a 3DP scale). The size and shape of the object needs to be perfectly suitable for the function and endlessly intriguing for the eyes
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1) 1) The first image really highlighted the acute angles that were possible with this machine. The curves and seemingly impossibly lines create such an organic feel. Such curves would require an in depth understanding of the software capabilities. 2)The second image highlighted the fragility of design that was possible. The tiny skeletal frame is simple and familiar as it comprises of fibonacci properties. 3) The third image is something that you want to pick up and look inside of as it doesn’t fully expose its complexity at face value. The pattern of interlocking components potentially printed as one, is only possibly using 3DP which is something that I wanted to really strive for
1) http://futuresplus.files.wordpress. com/2012/10/tumblr_lrxjb4ponc1r2h596o1_1280.png 2)http://www.theneweconomy.com/ wp-content/uploads/2012/04/3Dprinting659x380.jpg 3)http://melbournelasercutter.com.au/wp-content/ uloads/2013/05/9419397_orig.jpg
1)
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Customisable Speaker System
1)This 3DP lamp was beneficial in seeing how light reacts with the plastic material. Through proper understanding of PLA and ABS we can create something that isn’t stereotypical of the material properties of rigidity and ‘cheapness’. Rather we see softness and intricacy. 2)The medical application of 3DP through use of prosthetics and customised body parts and eventually what they believe would be a liver, is enough to blow your mind. The heralding of this kind of advancement makes ‘ole ordy’ feel so obsolete and primitive you want to give up... This work is incredible and was definetly worth noting,.However, the application of this would obviously require a thorough understanding of biology and I feel learning the operations of my 3DP deserves some kind of doctorate in itself...
1)http://assets.inhabitat.com/wp-content/blogs. dir/1/files/2012/05/nervous-system-hyphaelamps-4.jpg 2)http://blog.3dstuffmaker.com/wp-content/ uploads/2012/09/20120507-bespoke-legs1-1024x681.jpg
Customisation is something that is a needed for a number of different reasons. For many people, the use of prosthetics and other medical applications is a a day-to day necessity that costs a fortune . Lately, luckily 3DP is making this more affordable and accessible to a wider group of patients. However, it can also easily address wants in a consumer market where the individual is now always looking to separate themselves from the masses and 'consumer culture.' This in itself is a inverse concept, where the individual wants to subscribe to a certain look whilst simultaneously considering themselves incomparable. Sound and music are a unique things to everyone. Each individual has different preferences and tastes. Some individuals prefer a heavy base, others prefer a 'lofty' sound. Whilst there are constants and tolerances that will remain the same, it was important that I explored what could be optional. Options in sound could essentially create interesting aesthetics, it was my goal to create an object that was a complete reflection of its embodied sound, so that the aesthetic appearance would epitomise the ear experience and essentially the consumers taste.
INITIAL CONCEPTS: My boarding point for this ride was “Why 3d print” it was critical to consider the purpose of what exactly was being undertaken right from the outset. The question of “Why 3d print” was to be repeated time and time again. It became clear that it obviously was to repeateded many times more throughout the process. Initial concept pages explore the use and possible forms through 3d printing
bottles/capsules that internally sealed
Speaker with internal layering
physics of sound:
Shape
Looking at the way that sound is inhibited or enabled what interesting. It was important that the sound that was produced was matching the expectations of the end user
existing architectural influences and rectilinear forms
physics of sound and exploration of shapes impact on sound waves
Different shapes of course produce different sounds, discovering what the optimum shape was, was going to be a challenge
Amplification Through Form Parabolas Amplification Through Form This ceramic gramophone was something that really stood out to me as it highlighted the real effect that shape and form can have on amplification and the results of simple form. To me it was the perfect combination of old meets new. The simple placement of an iphone in docking spot with no electronics allowing a song to play, and the ability of form to convert that music into a clearer more amplified sound is a real achievement.
Parabolas have the best reflection and reverberation of sound. They receive from the direction traveling towards the parabola and are able to equally distribute that sound in the opposite direction. By placing earphones at these points directing the earphone toward the parabola wall it would be possible to get a distributed amplified sound output all without using amps of electronics in the product itself.
Amplification Through Form
Inhibitors/Enablers to sound Parabolas and cradle Through creating a parabola and placing an open output at the other end it would be possible to get a good sound output the next issue would be how to create this on such a small scale and what would the cradle for the OEM device potentially look like? The cradle could potentially be customisable and the device would dictate the scale and the composition of the form
The impact of shape and researching whether or not a particular shape acted as an inhibitor or an enabler to sound quality which was important to my design. I began looking at the way in which things could be whistled and the form that this concept could hold.
Transferring Sound
reverberation absorptions or reflection?
Sound doesn’t always travel in the direction that we intended or with the depth that we needed. This is due to many different factors including funnelling, absorption and warping. Funneling of sound
warping sound displacement
Iterations on how to transform and present the amplification of sound. Most effective structure to present the sight of sound is important.
RESEARCH: In order to get a sense of direction of where I was to go next with my speaker I had to consult the consumers to see if there was in fact a demand for my concept. This research would dictate what was essentially important to the design and what was to be customisable. To research I asked a series of questions that were relevant to my design and posted a survey using ‘survey monkey’ on the “2nd year RMIT Industrial Design” facebook page as well as the “addifacture” page
RESULTS AND INFORMATION
RESULTS AND INFORMATION The results of my research were compiled and directed the consequential steps in my design process.
The results of my research exposed that there was a demand for a customisable speaker system. There were a lot of existing speakers that were of course un customisable and had elements and features that were desirable.
WHERES THAT SOUND COMING FROM? There were many different speaker systems that are in a sense customisable to appropriateness to for a physical setting and location. Volume and sound quality is manipulated accordingly. Notably the main purpose for a laptop is usually ‘work’ yet 42% of respondents used this medium for listening to phat beats.
Paper Models my paper models were explored with my OEM component and were helpful in getting an idea of scale. The paper models revealed that I would need a lot of material to fully cover my OEM component which at the time I didn’t think would be so difficult...
STOP. WHAT. YOU’RE. DOING.....
YOUR. PRINTER. HAS. ARRIVED...... (INSERT INITIAL HAPPINESS AND AMAZEMENT HERE....)
Awesome how do I use it?
(IFIRST NOTED SIGN OF FRUSTRATION AT PRINTER)
Where’s assembly instruction manual?
Done all of that now what? WELL BEFORE YOU CAN DO ANYTHING YOU MUST: -Pull apart a power supply and modify it. -Install Marlin on your computer -Install Kissslicer on your computer -Cut lots of wires -Solder wires -Yell at the ORDBOT for soldering wrong wires -Make a massive wirey mess
STOP. YOU NEED TO DESIGN SOMETHING....
Level your bed. -Check your extruder temperature -Correct endstop placement -Reset marlin settings -Cold extrude using Reprap calculator -Have you levelled the bed? -Celebrate the fact you have light on your screen and a levelled bed with a beverage -Buy PLA -Yell at PLA for not extruding -Buy ABS
But the bed isn’t level and I’m not extruding properly!! (get so caught up you are no longer a separate entity from your printer. Printer is no longer ‘it’ ‘I’ am the printer. Printer is an extension of self....)
oh my...
First Test Prints: The first test prints helped in demonstrating the angles that were possible with Red Rocket. These prints were also in PLA and had my printer running with a bed temperature of 90degrees and a extruder temperature of around 170-190 the material of PLA is usually around 1.75mm. All of this information and more needed to be updated in my kiss slicer setting which took time to configure properly from information given from Scott/Nigel (Scigel) The first test prints were running well in PLA. However, they there were distinct ridges and these would not be able to be reduced without introducing a fan,fan mount and constant monitoring of the machine
(Have you levelled your bed lately)
What software to use? All of it.....
Me: Ok I want to make two circles Roller coaster Driver: (RD) Download Rhino 5
Me: Ok I want to make a loft? Rollercoaster driver (RD): install the grasshopper plug in., within Rhino 5
Me: for one loft? RD: yep
RD: loft in the right order....
I was hesitant to learn new software given the time frame but I really needed to be able to create interesting forms that were compliant with my speaker design. Lofting was done through setting a point on on the x,y,z planes and creating a shape with an origin at the centre of this point. The shape could be adjusted with a slider to move through the z plane with an endpoint at the next shape in the lofts beginning. The radius of the shape could also be adjusted with a number slider. The number sliders we introducing real scale and had to be carefully considered as the geometry of the overall form needed to realistically work
Loft Tools
Loft Tools
using the loft tools to create an object with a continuous surface using the loft tools to create an object with a continuous surface was difficult. The order in which I was lofting was carefully orchestrated. Creating specific angles in shapes on different axis of points was done and to loft back through the shape on the outside surface I needed to create the points in negative numbers. Which was a problem that took a while to resolve.
Grasshopper Barriers, Mesh Outputs, File configurations and Computer Crashes
For a while I was content with this design and believed that I could make this print on my printer. All I needed to do now was transfer it over into ‘Solidworks’ and slice it up to edit it. PROBLEM: ‘Solidworks’ hates meshes, like really hates them and wouldn’t transfer no matter what format I put it in IGES, DWG, STEP. I tried MeshtoNURB about 5 times each time my computer crashed. The only was I could get it into solidworks was as a pure ‘STL’ file. This wasn’t going to work....
The fact that it wouldn’t read in ‘solidworks’ meant that I would have to build my whole thing in grasshopper. I tried lofting the parts separately and printed of some parts in ABS
However, it wasn’t possible to simply ‘bake’ a loft in grasshopper this required me to download Weaverbird plug-in and use the ‘mesh-thicken’ properties.
This was useful in getting an idea of scale. From this, from this I gauged that I would probably need to almost double the size of my measurements for OEM component tolerances and also for the shrinkage that follows an ABS print.
Me: Ok I’ve made a loft and somewhat broken it down into ‘handle’ and two ‘leg’ components making three in total now I want to put a pattern on it and make it dotty... RD: Why dotty?
Me: I want a pattern that will effect the sound output and alter the acoustics
RD: Ok well download ‘panelling tools’ plug-in to ‘Grasshopper,’ Me: another download...
Panelling Tools The panelling tools will divide the surface into U and V slices. You can adjust the amount of panels using a slider. I found that the higher the amount of slices the less likely my design would be geometrically possible. By keeping the slice lines around mid 30’s and 40’s I could compile an achievable design.
Connecting Panel to Curve. Creating Grids
The panel needs to be connected to a curve. To do this I needed to create a circle with a radius that would cover the whole exterior of my design.. This would allow the Grid to be understood from the top to the bottom of my speaker.
To create a panel you need to decide what you would like to panel. This involves creating a pattern. I devised a very simple panel that was set on an x,y,z point in rhino. At this point I created a square shape and repeated the square shape on different points. The squares needed to be rotated so they were fully covering the surface. Each square was then extruded and capped. At the origin of each of these squares I created a circle with a radius below 2mm. The circles were then snipped
DESIGN CHANGE?: My design was then changed as I recognised that it wasn’t going to be possible to print in one print and get the support material accurate enough to create the design I wanted. I was effectively now designing around the limitations of the printer but still trying to push the software limitations as far as I could
loooking good (2hrs in)
CHANGE REVISION: Why: printer limitationsof size -time limitations -inexperience in creating support matterial Thats alright CHANGE TO WHAT? A hexagonal shape that would still involve an internal loft, meeting the why 3DP criteria but also with an intenal section that would encapsulate the speaker. Essentially sealing off the OEM component using 3DP
what layer is it up to? (2hrs 30mins in)
Spectacular fail.... This spectacular fail was a great learning curb. I was a week away from deadline and still didn’t have a completed design.... At this point I felt completely vulnerable at at the will of the 3DP
Spectacular fail....
(4hrs in)
The first thing I needed to do was to peel back my idea. I needed to go back to my original concepts and find out what was vital again. With this in mind I abandoned the over complicated design that I had of inserting a component between layers and focused on how I could effectively achieve my key essentials.
Dotty Variations Atempt at cone Variation I had to maintain the different acoustic variations and dots and the hexagonal shape. I had previously tried to create cones in the panelling tools but had been un successful as I could not get the cone to connect to the surface of the square extrusion.
The loft had serval different components but I still wasn’t happy to disregard my enclosed speaker concept I continued trying to work this in. I still hadn’t worked out how I could connect these lofts though.
Cones Complete/ Attempt at Loft Stitching Patterns I eventually managed to connect the to the cap surface brep by offsetting the cone at the height of the extrusion (2mm) and connected the two in another panelled pattern. I wanted to try two separate lofts one with cones on the inside surface of the shape and the other 1 with dots on the exposed outside surface Whilst it seemed that the lofts were joined in grasshopper when placed in a magics fix it could not work properly
I printed the pure conical design. However, it seemed the cones weren’t establishing a proper base for the rest of the speaker. The printer failed to print this 4/5 times before I decided to add another loft around the bottom surface that was planar and separate from the cones and dots.
Cones and Separate Lofts
The planar loft on the bottom surface I had now created four separate lofts as I discovered that part of the internal surface would need to be planar as well and could not have cones. This was to allow for the speaker to be placed in its allocated spot.
I needed to update the internal two ending lofts to being a circle and it was a possibility. Having the speakers enclosed would mean that I would have to print the connecting prints completely
Enclosed Speaker System The test print for the enclosed surface worked. This print is important in exposing that the enclosure was a possibility.
REVISED CONFIGURATION OF DESIGN Separating the Lofts would not have been possible as I could not find a proper input mechanism that would allow me to effectively join the lofts and have them all work efficiently. I abandonded the separate lofts and instead changed the internal surface at the top to a circular design that would provide an appropriate holder for the speakers
through grasshopper. If I was to print completely in pattern I had no way of offering the jack and and USB elements to the product as I could not transfer my file into ‘Solidworks’ and edit it.
One singular loft... Panelled... Patterned... Working... Printing...
yesssssssss
Roll Me Component Initially the power board extruded from both sides of the cylindrical part. After printing this part out and trying to fit it into an existing part was I able to learn that the board was too long and it was uneccessary.
To get around the problem of not being able to use the Jack and USB connection I created a separate component in ‘solidworks’ Initially the ‘Roll me’ component and the power board holder were separate parts. Only after doing several prints did I decide it would be more effective if I tried to join these two parts and hold the power board in place through using one print rather than using an adhesive to try and an stick these parts together.
Only through several failed prototypes was I able to effectively create an enclosure that would hold the power boards of my speaker system and was small enough to fit inside the two side components.
The separate components meant that the powerboard holder part needed fillets to fit inside the cylindrical shape. Having two separate parts also meant that there was a 4mm gap between the USB and jack inputs and the outside wall. This was too much, and made my whole effort futile
So I joined the parts...
I decided to add variability in this design through being able to alter the font and text of the object
Support Material Support material was crucial to my design in ensuring that my measurments were 100% accurate.
Acetone Sauna The parts had visible layer lines. To combat this I decided to steam the parts in acetone. To do this I placed a tablespoon of Acetone in the bottom of a glass jug. I placed the jug on a pan on the stove. I heated the pan up on a very low flame.
Component arrangement. Internal arrangement of the components was tight
Acetone Sauna cont... I dangled the parts over the top of the jug using wire and hooked the wire to the outside diameter of the jug I watched the part closely for change and within a minute the lines began to smooth out. I repeated this process for all three parts leaving them in the steam for around 5 minutes each.
Assembly The mercury switch ended up being an integral component in my design. It really affected the overall aesthetics of my design and it was important that I showcased this as well at the LED light placement.
Assembly
I researched into effective glues for sticking the ABS parts together. From this I found that the most effective glue was ABS mixed with acetone. -I found some ABS torn off support material and used this to mix into a tablespoon of acetone till there the mixture was slightly peaking and reached a ‘clag-like’ texture.
Me:I want to make my software adjustable in Touch OSC
RD: Why Me: To show the variable options in my design dotty, circular, hexagonal, cones bluetooth and power inputs RD: Ok you’ll have to download Firefly and Install OSC Editor Me: When I tell my computer this, I think he’ll kill me
Me: He’s already angry at this data>
Me: How do I bake it RD: you have to download lunchbox... Me: .....
So that OSC could communicate with with my computer I needed to create an Adhoc system (which dropped out constantly).
Lunchbox To 'Bake' the geometry I used lunchbox 'object bake'. I just needed to set a true false boolean toogle and It would bake when I clicked on each individual selection.
Touch OSC: My Touch OSC configuration was becoming overwhelming for my computer. Updating the components and baking them was proving to be a timely problem. I also ran into massive problems with the interval timer and could not work out how to control this.
How I Approached The Brief Overall There is constant evolution and development occurring in design. Each day the consumer demands something new, something different, something innovative. Till recently it hasn't been possible to meet the individual needs of these consumers through a broad scope. Designers are one of the many benefactors of the advancements in three dimensional printing as it provides the perfect platform for customisation of products and creation previously considered mathematically impossible. Whilst it was seemingly so possible to create so much and have such varied outcomes at the start of semester the technology is still embryonic a lack of reliability on the Ord Bot was a factor. My design may not be the 'best use' of 3DP systems, although it does showcase the application of potential customisation in sound. Eventually I would like to further this design when time allows. I think seeing and encapsulating sound and selling it is such an interesting concept.
To address individual needs I focused on the most commonly changed aspect of sound which was bass. Bass let off a kind of vibration that reverberated and reflected. This was not confined to the unit itself, but through research I found “hits the bones� of the listener and which is something that people like to be in control of and adjust depending on the setting. Through adjusting the aperture of the module the customer would be controlling how much bass they would be letting through and what this equated to in an everyday sense Big party = big dirty stinking bass Beach lounging= soft acoustic To distinguish between bass and acoustic I created two simple achievable outcomes cones and holes. Holes: Allowed sound to escape and created and open ambient sort of feel Cones: Reverberate of each other and reflect sound, but when funnelled creates a bass feel
Design Outcomes....
Eventual Aims A utopian design would encompass all of the sounds that essentially make the listener fall into some kind of beautiful trance on a deserted island with their favourite tracks and tranquil waterfall. I wanted to create something that could be picked up and looked at and that wasn't easily recognisable, that had an element of surprise. Whilst my concept of sound and beautiful listening was one thing I wanted to meet the demands of a broader audience through a flexible form.
Throughout the design process I could not think of an appropriate name for my design. I chose 'Dim' because the word was relevant to both sight and sound. To me 'Dim' was a hybrid of the senses I was trying to physically recreate. Dim also implies that the object can be altered, 'dimmed' or 'brightened' according to the variables that were placed in it
Dim
A big thanks goes to the crew at T.R.A.M.P (The Rustic AMP)
The ladies and lad here all helped me and eachother solve problems troubleshoot and remind eachother to eat food
ABS gets everywhere
Also a big thanks to the dedicated staff who let us raid their tools. Hack their brains. And ask them elementary questions at 1am over the addifacture facebook page . Their commitment is greatly appreciated
end. by Nicola Liston S3377561