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DIGITAL DESIGN + FABRICATION SM1, 2016 DIY Cone Sleeping Pod

Module 4 - ReflectionZoe Bratcher

787252 Michelle #9

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1.0 Ideation 1.1 Measured Drawings 1.2 System Analysis 1.3 Rhino Model 1.4 Reconfigured Material System 1.5 First Sleeping Pod Sketch Designs

2.0 Design2.1 Design Development2.2 First Design Proposal2.3 Precedent Research2.4 Second Design Proposal 2.5 Second Design Proposal Rhino Model2.6 Prototype & Testing Effects

3.0 Fabrication3.1 Reviewing Design 3.2 Design Development3.3 Final Developments3.4 Prototype Optimisation3.5 Fabrication Readings Influence3.6 Final Rhino Model of Design3.7 Fabrication Sequence3.8 Axonometric Assembly Drawing 3.9 Possible System Applications3.10 Final Model3.11 Folding Instructions

4.0 Reflection4.1 Design Review and Reflection

5.0 Appendix 5.1 Credit5.2 Bibliography

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Introduction

Brief To design a sleeping pod/sleeping aid that defends the idea of personal space and uses the panel and fold material system.

AbstractOur project centred on the idea of creating an environmentally friendly and easily repeatable design system out of simple materials that could be easily sourced. We focused on the idea of using the University Of Melbourne’s Student Union’s magazine: Farrago.

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1.0 IDEATIONIn Module 1, I explored the “panel and fold” material systems. Using an expandable folder as an introduction to the system, I analysed, measured, and modelled the folder in order to get a thorough understanding of the system and expandable mechanism. From this analysis, I was able to create a reconfigured sketch model based on the “panel and fold” material system, and begin to sketch out the first lot of ideas on the journey to the final sleeping pod.

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1.1 Measured Drawings

260 mm

80 mm

15 mm

140 mm

30 mm

Bottom View

Plan View Elevation View

Top View

Scale (all Images) 1:2

in order to measure the expandable folder, I looked at the shape and decided that as the shape is very boxy and flat, the best method to measure the folder would be to manually measure the dimensions using a measuring tape. This method was used to produce all of the drawings.

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Side View Folding Mechanism Scale 1:2

The folder’s most interesting panel and fold element is from the expanding divider mechanism. It fans out in profile when the front is pulled away, with the bottom staying the same width, and the top dramatically increasing in width. Although the folder closes so that it is reasonably flat, it converts to 3d when pulled open to create volume that enables storage.

1.2 System Analysis

Top View Folding Mechanism (Closed)

Scale 1:1

Top View Folding Mechansim (Open) Scale 1:1

Folding Fan Mechanism

15 mm

420 mm

Folding Mechanism Scale 1:2

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This Rhino model of an expandable folder was done to both further understand the expanding system, and also test my 3d modelling skills. The design served as an abstraction of the reality of the actual folder, simplifying the materials and shapes through basic shading. (Scheurer & Stehling, 2011).

1.3 Rhino Model

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1.4ReconfiguredMaterialSystem

This sketch model was developed to further explore the panel and fold material system. It was inspired by the folding expandable mechanism present on the sides of the folder, attaching each side together and then closing one of the ends to create a funnel shape of substantial volume. This was replicated several times to create the final model. The many combined cones gives the final model a squishy element that bounces back when pressure is placed on it, maintaining its shape and stability.

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1.5 First Sleeping Pod Sketch designs

Origami Reclining Pod with Screen Supported Standing Sleeping Station Reclined Diamond Privacy Pod

This pod was designed to replicate the folding of paper and origami, folding around the person inside. It also featured a privacy screen that can be folded to different angles to suit the user. This pod restricts unwanted contact from behind, and is built up around the sides to effectively hide the person in the pod.

This pod was designed to replicate a boa constrictor, wrapping around its prey. The design wraps around the wearer’s body, providing tension that helps keep the user supported while standing, and is attached to a vertical space where the user gets ‘strapped’ in. This standing pod gives the illusion of personal space by blocking the eyes of the wearer, decreasing their notion of ‘personal space’. The pod also bumps out around the wearer, giving additional space in their most crucial areas.

This pod was designed to fold around the user, swallowing them inside. The ‘blanket’ area is spaced above the legs to give them uninterrupted room, while the top section is fixed and closed on the right, and mostly closed on the top, stopping both easy physical and visual intrusion. The design gives the user plenty of space for themselves, but also make them feel relaxed and isolated, causing them to be less on guard. When a user is inside the pod, passers-by would be able to see anymore then the person’s shoes.

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2.0 DESIGNGroup Members: Amanda Sam & Charlotte Young

In module 2, a group was formed to further our pod ideas, and the sleeping pod design was created. From this we began experimenting to find a form that could be used as a paradigm from which the final pod would be developed. We decided played with a few different materials, before settling on the concept of using the University of Melbourne student magazine “Farrago” to create a sleeping pod with a deep connection to the university that was also environmentally friendly, and also was easily folded from the magazine.

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2.1 Design DevelopmentAs a newly formed group, we began looking at all of the work everyone had done for module 1. From this, we were able to look at two of our sketch models in order to begin focusing in on our concept. The first one (Young, 2016) was developed from folding a magazine to dramatically increase one end in thickness while the binding side remains narrow. This capitalises on the strength of the magazine bind to keep the model together. The other sketch model utilises individually folded cones that are interlocked together.

These two models formed the genesis to further develop magazine folding into cone-esque shapes that could interconnect. We then began using some University of Melbourne’s Farrago student magazines for some folding experimentation, but quickly realised that using these magazines could have a number of benefits to the final pod. Firstly, the magazine caused a specific connection to the site for which the pod system was being developed. Secondly, Farrago magazines have a monthly turnover, leaving quite a few left over that are then thrown out when the new edition is released. This means that the project could be quite environmentally sustainable. Thirdly, Farrago magazines are quite easy for students to come by, and thus, with some instruction, students could replicate the pod for their own use.

From using the Farrago magazine, we were able to come up with a cone–like shape that was folded from a number of pages ripped out of the magazine with it’s spine. The cone was then stuffed with cotton to make the shape full and bounce back when pressure is placed and then removed on the cone. The cone folding method is outlined in detail on page 36.

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2.2 First Design Proposal After the basic cone shape was created, we began to formulate the ways that many cones could be joined together. After making a few sketch models of cones, we began to place them around the body to see what looked good, and what was comfortable for the user. From here we discovered that placing a cone on both shoulders, joined in the middle created a neck rest that was very supportive of the head. This also created a visual spikey effect in elevation, this stops people from getting too close to the users sides, keeping them further away and defending the user’s personal space.

We also played with the idea of adding a smaller set of cones in front of the neck to stop the head rolling forward when trying to sleep. However, after some discussion, we decided this was an unnecessary element, as if the person using the pod is at least slightly reclined, their head is unlikely to roll forward at all. Another design component we began playing with was a separate headpiece element that would include a retractable screen. The thought was that this screen would help protect the user’s privacy when using the pod, stopping people from seeing in. Whilst the headpiece was a necessary element to hold the screen in place at the top of the head.

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From the basic shoulder piece, some sketches and a simple rhino model was developed, to further explore how these cones could be positioned around the head to give the head more support.

Isometric View Elevation View Front View

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2.3 Precedent ResearchLe Corbusier Puppet TheatreHuyghe + MOS Architects, 2004Interlocked highly strucutrial individual pieces

From Le Corbusier Puppet Theatre, the idea of the cones strengthened. The puppet theatre was constructed through having many diamond and triangular shapes interlocking together. These are normally quite structural shapes, and when bolted together, it creates a very strong structure. This could be applied to the cones. Each one is quite structural, but when interlocked together, they have the potential to become incredibly strong.

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2.4 Second Design ProposalAfter our earlier sketches, the pod began to take on a more full form consisting of two elements, the main structure of several interconnected cones, and privacy screen that was built into one of the cones. The ultimate form took up an asymmetrical design, with many cones connected together to create a superstructure. This design was built up more on the left hand side due to our model being slightly more sensitive to intrusion on her left side. However, the design could be customised by anyone making their own pod to take into consideration their own space requirements. The design will feature a board that will function as the back of a chair that can be slotted over pre-existing chairs, and then secured around the back to keep the design in place.

Isometric View

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Top View

Front ViewRight View Left View

2.5 Second Design Proposal Rhino Model

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2.6 Prototype & Testing Effects

A prototype segment of the key back of neck support and a protruding element was developed in order to further test if the concept would work or not. It was created from two cones linked together using thick wire, and a portion of a third cone protruding from one of the other two. To further support the joins, papier mâché was to secure the pieces together.

The prototype was very effective for supporting the neck in tests. The size of the centre join was very effective for pillowing the convex of the neck as well as leaving enough room to allow the head to comfortably move around. The stuffed cones also recovered quickly when pressure from a head was placed on them, managing to bounce back into shape due to the heavy density of the stuffing.

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3.0 FABRICATIONGroup Members: Amanda Sam & Charlotte Young

In Module 3, the focus moved to confirming the specifics of our design and joining system, as well as optimising elements to ensure quality during the fabrication process. It was also important to make sure the construction system was easily replicatable. This would allow people to make their own version of the structure, that takes their own personal space ideals into consideration, creating much larger or smaller structures then the one we created. The module concluded with a functional model of one possible design, and the development of instructional drawings to aid others in the creation of their own designs.

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Following the completion of Module 2, the group decided that the best way to proceed was to focus on the structure acting like a pillow, but with elements of personal space and privacy included, and to create an easily duplicable system, so people could make their own cone pillow structures adjusted to their own personal preferences.

This could include potentially using different sized cones (Maybe getting different sized booklets/magazines to use such as A3 or A6 size), positioning the cones differently, or using more/less cones to create a bigger/smaller structure. For our model, we decided to make a mid-sized structure, built outwards around the sides of the face to block people from approaching the face, rather than upwards and over the head as suggested in module 2.

To further streamline the design concept, we decided to remove the screen element of the design, as it caused a claustrophobic effect for the user, and also created an unnecessary design element. We also decided that the papier mâché joining method looked messy and also made the design too hard to replicate for others using the system, and a simpler joining method would be preferable. We also decided that the cones needed to be slightly more developed, firstly to figure out if there is an optimum number of sections to fold for the cones, and secondly, to develop a fold to create an interior ‘cap’ for each cone segment. This would allow the cones to be stuffed at a high density without any stuffing falling out, and also allow the design to create a more streamlined aesthetic.

3.1 Reviewing Design

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3.2 Design Development Interior Fold Cone Size Joining Cones

In order to resolve the need for holding in the cone’s stuffing, we added in two additional folds to each page, that caused a ‘cap’ to be created in each cone segment. This is folded before the segment is created, and then once the segment is finally folded and stuffed, the cap is folded over the top and attached to the other side. This creates a neat finished look to the cone, and allows the interior cotton to be stuffed in at a high density securely, so no stuffing will fall out and the structure will remain strong.

It was necessary to more thoroughly examine the size of the cones in order to figure out the optimum level of stuffing required to make the structure bouncy due to optimum density. We discovered that 8 segment cones didn’t allow for enough stuffing to make it comfortable, whilst 12 segment cones were impossible to stuff with uniform density. Therefore, we decided on cones with 10 segments as they could be stuffed uniformly quite full, which allowed them to be comfortable and bounce back when pressure is placed on it.

In module 2, we had joined our cones together using Papier Mâché, however this was messy and difficult, so we went back to thinking about how we could join these cones together. We briefly explored the idea of joining them together using ropes, before going back to look at options involving paper. We discovered that paper was at its strongest when rolled tightly into a rod, and we found them very difficult to bend or break in this form. Therefore, we decided to implement this into the joining of the cones. We thought that if we inserted a rod between cone segments on each cone, it’d create a very strong join that was thematically relevant to the overall pod. This required a small change to the folding method, instead of folding each segment against the magazine spine, the folds were moved to be 1cm further away to allow space for the rods.

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To test these developments, we created a new functional prototype using 10 segment cones and joining them together using the paper rods. It was very important that the joints were very strong to ensure the stability of the design, especially as we were using paper; a rather fragile material. We utilised multiple rods to join the two main cones together, one through each segment of the cone, creating a very sturdy joint. The rods were held in place through very tightly stuffed cotton around it. The tight cotton made the cones quite supportive and comfortable to rest your head against, and also made the paper bounce back when the pressure was taken away.

Additionally, this design doesn’t require any specific joins to the chair, and instead rest between the user’s shoulders/back of the neck and the chair or a wall. This means that the cone structure could be used anywhere, against walls or on any chair that has a back that goes to about neck height.

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These developments were then used to create a new rhino model implementing the basic shapes of the cones and the new rod joining system, to further understand how the system could work for a larger pod with more than two cones.

3.3 Final Developments

Joints Cones

The new joining system very successfully continues the visual language of the farrago paper, whilst also being highly durable and creating a very strong join. These thick rods really reduce the flexibility of the structure, which is a good feature, as otherwise the whole structure would twist, causing the design to fail and quickly disintegrate. The rods also are fairly logically placed between the two cones, which will make the system very easy for others to understand, and increase the likelihood that people will try and make their own versions.

After Module 2 we ended up altering the cone structure slightly, attaching the segments via the edge of the paper rather than overlapping them. This created a wider and less pointed cone with a softer surface area that would be more comfortable for users to place their head on. It also is a more forgiving shape that is less likely to develop additional unwanted creases and bends when pressure is placed on it.

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Optimisation for Effects Optimising for Fabrication Optimising for Materials

3.4 Prototype Optimisation

When we changed the folding method for the cones in order to implement the rod system on page 24, we realised that by folding 1 cm of the magazine spine to create space for the rods, that the tips of the cone was no longer pointed, and instead became flat. We realised that this would counter the beneficial effects that the cones point previously had, which caused a self-preservation effect in others, where they would give the pointy cone a wider birth; increases the user’s personal space. The Farrago magazine also helps allow the design to blend into the university environment, as it isn’t a solid colour, it looks more inconspicuous and doesn’t stand out. This would allow the user to not feel like people are watching them whilst they are trying to sleep.

We made two small changes to our design for the benefit of fabrication. The first was to use a skewer to roll the paper rods. This made rolling the rods much easier and quicker than doing it by hand, and also made them tighter and of uniform thickness.

The other change came about after realising that our prototype models would quickly develop small rips and tears around the edges, this worried us and we were afraid would affect the durability of the design. Therefore, we decided it’d be good to cover the edges of the paper with tape in order to make edge rips impossible. We first tested this idea using packing tape. This worked effectively, however, the tape caused a very noticeable gloss around the edges of the paper which detracted from the paper effect. Thus we decided to change the tape we were using to scotch tape. This created the same functional effect, but was almost invisible. This meant that the paper effect was preserved.

The features of paper as a material are reflected in the overall model design. Paper is pointy with sharp corners, smooth surfaces and is very flexible, these are also features that are visible in our pod design.

Each Farrago is maximised to use all the pages, (3 10-segment cones can be made per magazine, as well as a few rods. so all pages are used). Ultimately, by being careful with our materials we can make our pod using only two Farrago’s and 3 smaller union house pamphlets for the smaller cones.

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3.5FabricationReadingsInfluenceAs the fabrication process was done entirely by hand we had little use for digital fabrication processes such as 2d, subtractive or additive fabrication (Kolarevic, 2003). However, we did still utilise CAD technology through Rhino (Iwamoto, 2009) to assist us to develop our final product. This software allowed us to easily experiment with the placement of the cones and rod intersections within a 3d space.

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3.6 Final Rhino Model of Design

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Our final design consisted of two main elements: the cones (two different sized cones were used), and the rods functioning as a spine of the design. The Rhino design was produced to show the arrangement and the angles of the elements of our interpretation of the system. The arrangement of the cones are not random, as every cone has a purpose. The side cones are positioned around the head and are too support the head at rest. While the two large back cones are the backbone of which all other cones are based, and support the back of the head. The side cones are also built up to obscure the users face in profile, to make them feel more private and increase the perception of personal space.

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3.7 Fabrication Sequence

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3.8 Axonometric Assembly Drawing The final sleeping pod design is created from 6 paper cones (3 large cones from A4 booklets, and 3 small from A5 books), as well as 5 bundles of sticks to create the joining of the cones. To create the pod from these elements simply insert the small cones into the corresponding sticks and then insert them into the larger cones so they connect as shown

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3.9 Possible System Applications

The paper cone and rod system could easily be changed and interpreted differently by other users making their own designs. Depending on their preferences, they could build the design larger or smaller, in different directions, or potentially even implement magazine/booklets of different sizes to create more cone sizes. These images represent some potential ideas about how other designs could be built up to create unique pods. The only uniform element is the two large supportive back cones, which is a key supportive component of the design.

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3.10 Final Model

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3.11 Folding Instructions

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To fold the cones, rip out a group of 10 pages from the Farrago with the spine still joining them together. Then, for each page follow the folding instructions above to create each cone segment. Each dashed line represents the next fold to make, while light grey lines represent creases in the paper. When finished folding attach each side of the paper so that each red segment is attached. When all of the pages are folded insert rolled paper rods through the hole in the bottom of each cone segment, and then tightly stuff each cone segment. When this is complete pull the protruding cap paper over so the smaller fold tucks between the stuffing and the paper and attach.

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4.0 REFLECTION

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When reviewing the work done throughout the semester, I find myself left with mixed feelings. On the one hand, I’m proud that we came up with a design that a quality that was noticeably ‘different’ from all other pod designs. On the other, I wish I had been a part of a project that had to utilise digital fabrication techniques such as laser cutting (Kolarevic, 2003), to create a more dramatic sleeping pod concept.

However, by hand-making our design we were able to inject a high level of old-school ‘craft’ into our project (Bernstien & Deamer, 2008). Most of our experimentation throughout our design process was done through physical prototypes, and for our final model, we were forced to put a large amount of care and time to ensure that it was crafted to the highest possible quality. This was particularly difficult due to paper being the material, and being highly susceptible to dents, bumps and rips. This created a high level of risk during the crafting process, one wrong move could mean that we would have to start that section again from scratch. However, it also meant that our design ended up truly being original, and even if someone set out to replicate the design, they would end up with a slightly different, unique cone structure.

The process of making prototypes really helped us work our way through the design from beginning to end, allowing us to think through issues and develop the idea. It allowed us to continually work our chosen material, causing us to become experts at the folding process that would transform the magazines into the cones (Charny, 2012). At times, the constant folding was exhausting, but a few weeks into semester, I began to find the process quite meditative. I feel that it would have been possible to build up the pod to be much larger, to make it much more obviously defend the user’s personal space. As it is, it functions in more symbolically. The pointy elements of the cones encourages people to stay further away from the user then they may otherwise. Also the structure blocks outside views for the user, this effectively ‘hides’ the view of the people, making the user feel like they have more personal space then they might actually have (Sommer, 1969).

In conclusion, I thought that this subject was an interesting look into the design process of an object. It also allowed me to learn more about some computer programs that I hadn’t previously such as InDesign and Rhino. I do really wish that our sleeping pod could have been created using digital fabrication means, but unfortunately, being a part of a group means that sometimes development doesn’t go the way you wish it will. Therefore, I will have to make attempt to learn more about digital fabrication in my own time.

4.1DesignReviewandReflection

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5.0 APPENDIX

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CREDITS Zoe Bratcher Charlotte Young Amanda Sam

Page Drawings Computation Model FabricationModel Assembly Photography Writing

Graphic Design

Cover Z Z Z2 Z Z3 Z Z4 Z5 Z Z6 Z7 Z Z8 Z Z Z9 Z Z Z10 Z Z Z11 Z Z Z12 Z Z Z Z13 Z Z Z14 A Z Z15 Z C Z Z16 Z A Z A C Z A C Z Z Z17 C Z Z Z18 Z C Z Z19 Z Z Z Z20 Z Z Z21 A Z Z C Z Z22 Z Z Z Z23 Z C Z Z24 Z Z Z25 Z C Z Z26 Z Z Z27 Z A C Z Z28 Z Z A Z Z29 Z Z Z30 Z Z31 Z Z Z32 Z A C Z33 Z Z Z Z34 Z Z Z35 Z A C Z A C Z Z36 Z Z37 Z Z Z Z38 Z Z39 Z Z Z

5.1 Credit

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5.2 Bibliography

Iwamoto, L 2009, Digital Fabrications: Architectural + Material Techniques, Architectural Press, New York.

Kolarevic, B 2003, Architecture in the Digital Age – Design + Manufacturing, Spon Press, London.

Bernstein, P & Deamer, P 2008, Building the Future: Recasting Labor in Architecture, Princeton Architectural Press, Pennsylvania.

Scheurer, F & Stehling, H 2011, “Lost in Parameter Space?” IAD: Architectural Design, Wiley, Vol 81, July, pp. 70-79

Sommer, R 1969, Personal Space: The Behavioural Basis of Design. Prentice-Hall, Englewood Cliffs.

Charny, D 2012, ‘Thinking Through Making’, in Danish Craft’s, Design & Making. Danish Craft, Copenhagen, pp. 29-37

Farrago 2016, Edition 3, Melbourne Student Union Media Department, Melbourne.