Module 3 virtual

Module 3 - Fabrication

Kirill Kokorin (643739), Kristie Hughes (608669) and Leah Tausan (641095)

Design Concept

The final design idea for our group is to use the panel and fold method to create a spiky, body armour which can be extended to provide the wearer personal space when he/she feels threatened or imposed upon. The idea of movement became incorporated into the design concept after reading Personal space : the behavioral basis of design by Robert Sommer (1969). Sommer describes how mental patients feel at ease in isolation but react defensively when approached by strangers. We decided to add functionality to our second skin design by creating a body armour which lies dormant but has the capability to become activated by the wearer. Another point which Sommer made is that ‘Personal Space is no necessarily spherical in shape, nor does it extend equally in all directions’ (Sommer, 1969). As a group we have discussed and evaluated that we all feel more threatened if someone approached us from behind (as we cant see them) and from the right hand side (as this is our dominant side.) Therefore we decided to develop a design that focused on these areas. Originally we intended to incorporate a hood to protect our head and block out sensory aspects of feeling threatened such as sight, smell and sound. Yet this idea was abandoned after it was realized that the hood design was not cohesive with the spiky body armor.

Precedent

To gain inspiration for our second skin design we looked into the defense systems of animals which use spikes to repel their preditors. Using this analogy created a starting point for our design. We incorporated a gestural defence aspect into our design based on our findings and following ideas about defining our personal space generated from Sommers article. We have created a second skin design which is able to repel intruders from the users personal space by using the panel and fold method to produce movement that enables the user control of their personal sapce.

Prototype 1 With our first attempt at making a self supporting structure that could be worn in order to protect your personal space, we kept it simple in order to address two complex design issues - how to attach the spikes to the body and how to create movement.

This prototype uses a string as a mechanism to make the spikes move. The spikes lay in almost flat panels and when the string is pulled they transition into three dimensional spike shapes. This idea appealed to us as it meant that the spikes can be activated when the user feels their personal space threatened and deactivated when they feel comfortable again.

In his TED talk, building the seed cathedral, Thomas Heatherwick refers to the importance of infusing soul and beauty into design, creating efficient designs that are appealing and carry beauty in the details. He demonstrates focus on materiality and functionality and thinking outside the square. Seeking inspiration from that which we are surrounded by to infuse soulfulness into our designs. By further refining our design through the making process we have been able to achieve a more aesthetically pleasing design that is capable of repelling others from the wearers personal space.

Prototype 2

Our second prototype is a more completed continuation of our first prototype. The singular panel that we made was replicated in Rhino to form a spiked cylinder shape that was fitted to Kirill’s arm. We chose the cylinder design as it was more structurally sound than other ideas. We have used eyelets and fishing wire as a mechanism for creating movement between the spikes and attempted a variety of connection methods with the aim of extending to spikes with minimal effort by the user. The eyelets also added an additional visual dimension to the design, making it look aesthetically pleasing as well as repulsive.

Prototype 2 - Digital Rhino Model

These series of picture show the process of making the Rhino model for Prototype 2. The structure of the spiked arm piece was modeled off the 123D catch model of Kirill in order to fit it exactly to his body like a second skin. After the basic cylinder shape to fit around his arm was created, it was paneled in order to create a dangerous looking spiked surface.

Prototype 2 - Fabrication Process

The fabrication of this model was our first attempt at using the paper cutter in the fabrication workshop. We found the unfolding process of the model on Rhino difficult as we couldn’t make it unfold in order, and therefore after unfolding it, had to reassemble it in its two dimensional form. The use of the paper cutter was straight forward except we encountered an issue with it not cutting properly as a previous user had broken the tip of the blade, Therefore once the design was cut we had to re-cut it using a cutting knife. This increase the human error of the process. Due of variable factors like this we have decided to send our final design to Fab Lab for cutting out.

Before the model was assembled we hammered eyelets into it in order to create a steady surface for the string to pass through. Having eyelets also prevents the paper tearing when the string is tightened to pull up the spikes as well a making it a smooth movement. The model was assembled using a combination of super glue and staples. The staples we simply used to reinforced parts where the super-glue had not bonded well and to save time. In our final model we will only be using adhesive substances for aesthetic purposes. Once the model was assembled, fishing wire was threaded through the eyelets and was anchored to a singular paper panel that could be pulled. This was done to avoid the fishing wire getting tangled us, as with the multiple panels of spikes, there were multiple pulley systems.

After presenting this design to our tutor Kim, feedback received was to make the spikes smaller to create a more volumetric design which contours the body.

Yet when our design was looked by Paul, he suggested to make the spikes bigger. Therefore as a compromise we have decided to make the slightly smaller.

Prototype 3 This third protoype was created in order to explore a new folding method. The panel used for this is one that has been from the back of the Rhino model.

We assembled this model in the same we have the previous two, Except once the spikes were up we realised that they could be folded up and down using an extra origami fold in one of the panels. This discovery informed further development of the movement mechanism and presented an oppurtunity simplify the design.

Prototype 4 A continuation of the idea developed in protoype 3.

With this model we continued the idea of the extra fold whilst creating a way for the spikes to pop up and down. We came up with a system that held the spikes erect using elastic bands which could then be folded down by pulling the fishing wire. This system was enabled by the extra origami fold in each spike and is completely the reverse of our previous design in which the spikes lay flat initially. As a group we have decided to go with this simpler, more refined method as it utilizes the panel and fold technique more. Using elastic also adds more dynamism to the model, creating more simple and effective movement.

Protoype 5

Prototype 5 is basically Prototype 2 but put together differently. We wanted to test the new string and elastic methods previously explored in Prototype 3 and 4 on a bigger scale, hence why only half of the model is strung up. We trialled many different ways to create the movement during this process using thin elastic and fishing wire.

Protoype 5 - Fabrication Process

When assembling this model we realized that we should have made tabs on each spike as the spikes now start in their three dimensional form and fold down to be flat. In the next Rhino Model we create we plan to do this, but for now we have had to create makshift tabs held together with masking tape and super glue. They do not look very appealing but they create the structural support we need to test if our new idea for assembling the model will work.

Protoype 5 - Fabrication Process

These images clearly show the new fold that we have put into each spike.

Another issue we have faced is that the longer spikes which resemble scalene triangles do not fold as well as the slightly smaller ones. Therefore in the new Rhino Model we create the spikes are going to have to resemble equilateral triangles, therefore being slightly more evenly proportioned.

Protoype 5 - Fabrication Process - Trialling Movement

Method 1: The first method we trialled was to have the elastic holding the spikes down. The idea was that when you pulled the fishing wire which was connected to the top of the spikes they would fold up.

Unfortunately because of the strength of the elastic and the positioning of the eyelets, this method did not work.

Method 2: The second method trialled was the reverse. The elastic was treaded through the spikes in a way to hold them up and the fishing wire was used to pull the spikes down, By positioning the elastic holes low and the fishing wire holes high we were able to counter balance the force of the elastic to create easy movement.

Method 2: Another issue with method 2 was that in order to make the elastic pull the spikes up we needed something preventing the elastic slipping through the eyelet. In this prototype i just attached an extra eyelet tied into the elastic band. Unfortunately this makes it look messy, so this method was abandoned.

Protoype 5 - Fabrication Process

Method 3 The final technique which we decided to use to create the movement of the spikes folding and unfolding was the simplest. Each spike is connected to the base, and hence held erect by a piece of elastic. Separate individual pieces of fishing wire are pulled to make the spikes fold down. The effect is that the individual wearing the second skin can hold the string tight when they are feeling comfortable, and when a threatening situation occurs they can release the string which allows the spikes to pop up quickly. This process can be repeated endlessly, allowing the user versatility.

Final Rhino Design

The final rhino model was essentially a complete rethinking of the previously explored design. Arbitrary spikes on a isometric shell clearly did not provide both the aesthetic and functional elements needed for the second skin design. Instead freeform surfaces were created around the back and arm which would themselves become part of the 3D skin. The use of freehand curves allowed for the generation of a much more organic and fluid design. Panelling tools was then employed in order to make the design truly spectacular through the idea of multiplication. Panelling grids around the respective surfaces were skewed in order to truly reflect how personal space changes around the body. A custom panel with just two sides would have been best for creating the design however the panels proved to distort when applied to the grids. Therefore a simple pyramid panel was used and then manually altered to suit the design needs. An idea was also generated for the hood element of the skin; however it was not sufficiently cohesive with the rest of the design.

Final Rhino Design

In further developing the rhino model, density of panels was increased while size was decreased in order to create a better sense of volume for the second skin. With regards to manufacture both the arm and back were divided into long vertical strips to which the successive spikes were attached. These elements were then unrolled with a single page per strip. The use of dashed lines greatly helped in creating the folds in the design as panels needed to fold in both directions. Tabs were then added for later assembly and the model was ready to be manufactured in the fabrication lab.

Final Rhino Design

More images of Rhino design and the un-folding process.

Technical Drawing of Arm Piece

The arm and back are created out of separate linear panels which are connected by a lab system which are glued together.

Here you can see the panels pulled apart and how they connect.

Each panel has a separate panel of spikes that are connected to it and are glued down by tabs.

Final Model - Cutting

Developments to the design included perforated fold lines which increased flexibility of the model.

We had complications with Fab Lab whilst creating our final model. We had placed each panel onto a separate sheet of card and they moved some components around which we did not consider occuring. We hadn’t labelled the project, this led to complications with assembling the model. Also the tabs we had created were too small to join some components together.

These problems were solved by labeling the bits of the model and taking on Fab Labs suggestion of using the laser cutter. The laser cutter provided cleaner, sharper edges which make the second skin look much more dangerous. By creating dangerously sharp edges the second skin repels others from the users personal space.

Fabrication of Final Model - Adhesive Substances

Figuring out what materials to use in order to assemble the model was a learning process in itself. We designed a tab system to make gluing the model together easier, yet getting the tabs to stick together was a challenge. Firstly we tried UHU PVA glue, this unfortunately did not dry fast enough or provide a strong enough hold. Super Glue did not work well either, the drying time was alright but we found that the bond it created was too brittle and easily unstuck under pressure. Eventually through trial and error we discovered UHU multipurpose adhesive, which was a nice middle ground between PVA and Super Glue.

This glue took half the amount of time to dry in comparison with PVA and provides bonds which are more flexible than Super Glue. Another tactic that worked on instances when the glue just wouldn’t stick or we made the tabs too small for the glue to stick was to use a small staple to hold the tabs together. After stapling the tabs we have used black permanent marker and paint to disguise them against the black paper.

Final Model - Assemblage

These series of photos show the progression of our of the second skin. After gluing the individual panels together using UHU multipurpose adhesive glue, we hammered eyelets into the design. These provide holes in which we can thread fishing wire through. It also makes the second skin look more interesting and more amour like as it reminds us of the chain mail worn by knights. After that the spikes were origami folded to enable them to fold down and pop back up.

The final step of the process was attaching fishing wire to the top of each spike in order for it to be pulled down and hat elastic in the center to counter this force by pulling the spikes erect.

Final Model

In order for Kirill to be able to wear the second skin comfortably, we made a type of strapping system with thick black elastic which looks around his shoulders.

As a last minute idea to create interconnectedness between the back and arm part of the design we have attached the strings that pull the spikes down on the back to the arm. Therefore the user can control the amount of personal space they want to create by easily moving their arm.

Final Model

The movement of the second skin was one of the most important parts of our design as it allows the users to be in control of their personal space.

Due to the complexity of connecting the two pieces together, the spikes in the arm do not have any movement. Yet we believe that this is overshadowed by the linkage of the arm to the back. We are pleased that as well as physically creating personal space, the second skin looks dangerous and threatening, repulsing people away from the user.