Take a Bite of My Ringo <3

Re-photoshopped poster of my Ringo Stool! Added some graphics to the seat to make it more coherent with the tessellation... I love the pattern I came up with! :)


P.S.
Ringo means 'apple' in japanese! See the connotation?

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Final Presentation

Here is a collage of some fellow students work. Click in to see full size.

During the presentation Siobhan asked everyone what they'd change to the design if there was a second generation stage. I guess with mine it would be incorporating the pattern into the seat and perhaps work with the rocking stability of the form science.

I think I enjoyed this project overall because it got me interested in understanding material attributes (esp. something as unique as Mg) as well as overcoming the fear of calling up manufacturers. This project gave me insight into how different materials have different design possibilities and how new manufacturing technologies can be worked as an asset not a restriction.

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Transformation

Due to Rhino restrictions my rocking chair form came down to this:

Before I was going to 3D-prototype it, but after speaking to Tony I realized how expensive it really is so I got rid of this uneconomical idea...

Then I went through more thinking processes and referred to my InDesign magazines for some inspirations too. This was when I called up ManufactureLink to confirm the final design.

I also came up with a new pattern!! Because Rina said I should simplify the previous one and I struggled quite a lot to create a pattern that's a combination of organic and geometric... and I came up with the following design (which I am very proud of because it's rather original and inspired by hexagonal tessellations AND definitely after some toil to get around to!):

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ManufactureLink.Com

I wanna recommend everyone this website I came across http://www.manufacturelink.com.au/.

It's a special service that provides expert advice in manufacturing technologies to ANYONE - yes anyone! So they are happy to talk to students as well as clients / designers who have questions they need professional critiques on. This saves trouble of calling up actual factory managers who might be busy or absent to really give you comprehensive advice.

So I called up the number (in QLD) and a guy named George Pofandt picked up. I actually called them twice because I struggled looking for suitable processes to manufacture my design. Anyway, so George helped me to resolve the following issues:

1) Thickness can hold a person's weight?
I told George I am intending to use 3-5mm Mg sheets produced by the Twin-Roll Casting technology patented by the CSIRO and he said it should be strong enough even with cut out tessellation! Yay!

1) How to make the bottom bowl out of Mg sheet?
After explaining the bowl structure to George and stating the manufacturing difficulties that it could occur, we came down to a solution of Flow-forming.

It's a process similar to metal spinning but of metal sheets; and because my bowl curves around the end I would need to firstly cut the sheet at a calculated size and shape and then CNC-spun around a mandrel to produce a ‘bowl’ of 1/3 of a revolution. During flow forming, the sheet metal is cold worked, changing its mechanical properties i.e. its strength becomes similar to that of forged metal. This step is repeated to produce a series of thirds and then paired up to be welded at the seams to complete the bowl component.

2) Laser cutting of Mg? George actually told me that water-jet cutting is more suitable because laser cutting is what could ignite the magnesium during the process (and you'd think Mg would react to water! But apparently not water-jet cutting.); WJC also makes finer edge finishes so no extra sanding is required! So this would be how my pattern (modelled in CAD to be read by the machine) will be cut around the sheet bowl with the multi-axial cutter to produce a metal lace structure.

3) Assembly of seat + bowl components?

Because the seat is also 3mm which sits on top of the end curve of the bowl structure, George suggested me captive nuts & screws which could be snapped on quite easily and can be done manually to reduce unecessary machine costs.

I also asked if aluminium screws are ok for contact with Mg - and he said it should be ok if the Mg was pre-protected with de-corrosion bathes.

So thanks to ManufactureLink.com I got to understand more about the various processes available in the industry now in Australia!

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The Cycle of Re-think, Re-draw, and Re-make

During the one-week break, I went out and bought some metal shims and started cutting up the patterns for my chair design...


The pieces will be welded at the seams to make a hemisphere for the rocking body. Might have to iron the metal lace beforehand though. Even though I made it out of metal sheet I actually intend it to be slightly 3D and rounded in thickness.

However,

Due to Rina's absence, I consulted with Oya instead. I guess it's the subjective views... but what Rina liked Oya had doubts about:
Do the patterns of the seating net corresponds to the design of the magnesium body? (I explained to her about the William Morris concept, which, she thought I should simplify and abstract it down - geometry, radial, contemporary, etc.)

Then Andrew came along and questioned the following:
Does the hemispherical form really speak the rocking-chair typology? Does it confuse people in what it intuitively communcates?

Anyway, so I started re-drawing some ideas as well as looking for some existing rocking chair designs to try and understand the visual connotations...

I did come up with a better visual form, but couldn't scan it right now so gonna try and think how I am going to make it first (model + actual manufacturing process) and hopefully resolve something!!

Meanwhile Rina also introduced David Trubridge to me. He utilizes cut out pieces of wood riveted together to form really beautiful and organic products; the patterns in a way resemble what I am trying to express with the Mg malleability, so I went online and looked through some of his designs for external inspirations.

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Stage 2: Development

So yes I went with the rock chair idea and pushed it further.

In terms of manufacturing, I tried consulting the CSIRO but no response received... so I searched around online and found a process called RPM (rubber/plastic moulding) that 3D prints urethane masters which is then used as the mould for casting molten magnesium. This could be the alternative to my unprecedented FDM rapid prototype technique if it isn't considered feasible.

Anyway, here's my poster

Photos of my very drafty sketch model made out of paper card

Plus a random sintered / stereolithographed model and 2 very lovely lamps


I think my challenge now is to make a final 'exquisite' model. Rina pointed out the thin edges that could be quite uncomfortable for people behind the knee joint - so will need to perhaps add cushion / contemplate in regards to the rubber netting and how I should attach it to the magnesium frame.

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The World of Patterns

Thinking of how I can fully optimize the material of magnesium by means of Fused Deposition Modelling, I came up with the concept that: although magnesium was discovered in the 1600s, isolated during the 1700s and utilized for military applications during the World Wars, the period in between - which was the Industrial Revolution - was wasted. So I wanted to recontextualize that period to prove what could have had been a great utility of magnesium.

Hence I sought for some William Morris / Victorian pattern designs for my chair...


Then remembering from the exhibitions I went to, at that time traditional Japanese art also had some oriental influences on the western arts & crafts...

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Some 3D Printed Models

Looked through a variety of rapidly prototyped chairs to seek some inspirations...



Most of the designs shown can be found from http://www.oobject.com/category/3d-printed-products/

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There's Something About Maggy

Last week we presented our initial concepts for our second project: Material World.

Our material selection was Magnesium. At first we were like 'o no...' because it sounded like such an unfamiliar material to us. But after some decent research into it, we realized how important it is to us, and how unique it is as an earth metal:

- It's the 3rd most commonly used metal after steel and aluminium.
- Has high strength-to-weight ratio (lighter than most metals without losing strength)
- Low melting point; ignites in contact with air / water
- Corrosive in nature
- High viscosity (good surface features)

Just a few of these characteristics is enough to convince engineers of its utility; it has been applied mostly in automotive and aerospace industries where lightweight contributes a great deal to energy efficiency.

Anyhow, my proposed approach to magnesium is to bring it back into the domestic environment where common users can really start to acknowledge of its existance and significance in our everyday lives - to establish an intimate relationship on a physical and emotional level. Here are my 4 concepts (p.s. I don't know how the image converted to blue from orange after I uploaded them) :

DESIGN RATIONALE: utilizing Mg propoerties, a coffee chair is made out of sheet metal produced by the Twin-Roll process patented by the CSIRO (only feasible with the versatility of Mg; up to 3mm thin). The form takes the curvature of a saltwater fish (where plentiful of Mg is found) to reconnect it back to its history.

CLIENT RESPONSE: How is the sheet metal going to be bent after it's rolled? How can properties of Mg be taken further?

RATIONALE: Take the automotive form and bring it back into the home. Can be mounted onto wall so the function of the wheel still exists. First attempt for Mg to be manufactured using Fused Deposition Modelling (which is suitable for eutectic metals i.e. easily melted).

CLIENT RESPONSE: the form looks moulded / could be more exquisite in detail so that it appears to be ONLY for Mg and ONLY for FDM prototyping. But even beautifully detailed, will it still be able to hold the weight of 8+ wine bottles?

RATIONALE (really is supposed to be orange colour): Taking the mickey out of the fact that Mg can be found in fruits and vegetables, I came up with a thixomoulded rocking chair that's portable and can also function as a storage. The seating area is in fact knitted out of elastic material which can ergonomically accommodate to the seater's physique.

CLIENT RESPONSE: Interesting connotation; but perhaps the Mg properties can be driven further to really show its uniqueness. Perhaps a porous casing?

RATIONALE: Once again, to play on the fact that Mg can be found in (yes) chicken eggs AND the fact that Mg Oxide is used to coat heating elements. An organic form is conceptualized in full Mg casing (coated in silicone for cold insulation) and allows less user fatigue when pouring.

CLIENT RESPONSE: Why Mg? It can also be in other materials ... in other words this concept doesn't utilize Mg properties to a full extent.

**********

In conclusion, I think I have decided to develop further with the chairs and really look into the manufacturing processes that maximize magnesium's performance characteristics. Off to do some reallll thinking now...

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Exhibition Review 1

I think it's about time I should post up some of the photos I took at the exhibitions I went to.

First one was the Australian International Design Awards 2008 Exhibition; I visited this one simply because it was the first thing I saw after getting confused at where to go.

The criteria for the award was based on: innovation, functionality, visual appeal, quality, environmental impact, ease of use, and safety. I think fulfilling the purpose of all the above mentioned would definitely have to be something truly amazing.

Well, after thinking that I turned to the first section of display: a green-mold chair, a helmet, and a water bucket. At first I was like 'hmmmm' but then I realized these were designs from the PAST. Reading more into the descriptions I began to understand the functionality and how it made its mark in history on revolutionizing what was even more obsolete. I think with ordinary objects like these, people don't really learn to appreciate its existence and the convenience in life they bring; let alone the intellect behind its making. Just looking at how a simple form changes the entire impact of the solution is profound - from the ground-breaking surf fins by Metro Solutions to the EFTPOS device by Ingenico International convinced me of their eligible presence behind the glass panes.

Next I moved towards the back of the exhibition. It was the PowerHouse Museum Selection 2008. The designs on display ranged from eco-friendly windows to newly improved LEDs; some were designed by design graduates. I think this part of the exhibition is on the time of NOW - in the sense that we are now at a stage where sustainability is the new word that's pushing the frontier of design possibilites. The Lightway Window by Damian Savio uses transparent photovoltaic cells which powers OLEDs at night and can be deployed to use as a portable lamp; as seen below:

Then there were the innovations by students boxed in the next few displays. So far the exhibition flows clockwise starting from the entrance in chronological order, which I think has its own meaning of time travel. Anyway, the following displays showed some interesting technological innovations that improve the benefits of users, e.g. the Flaik personal tracking device for skiers and snowboarders created by CMD Product Design. This piece of electronic allows interactive data that digitally records and synchronizes the skier's performance & snow experience which can be shared on a web portal. This is the winner of the AIDA Top Accolade prize. Shown in front is a series of concept drawings of the design - I was amazed at the resolution! I think the professionalism in the pencil work is out of question; likewise the rest of the designs all showed a panel of the concept generation behind the final product, and I think it showed to some extent the respect to the designers and how they manifested the quality and integrity into their own works of avant garde. This was a good intention of the exhibition I thought, providing a good insight into the design process to educate and inspire viewers of all ages.

Finally I reached around the corner to find some FUTURISTIC designs - one dominant model was the Sunswift solar car designed by the UNSW Solar Racing Team! :D

I am not being biased but I don't really like how it's displayed in a corner - facing the back! Even though it's got a 1:6 model encased, a video coverage, 2 - 3 description boards plus a hero shot photograph - all this seemed kinda pointless when it's really not located at the pride of place! I guess solar cars ain't something promising five years down the track yet...

Coming out of the corner I came face to face a final set of displays on construction development. Something I am not that interested in but still took a quick skim through it. I stopped to take a closer look at the architectural model that was so refined in detail. It's really beautiful by itself; I don't think I can ever have the hands to make such intricate objects! (yes, I have a lot to improve in terms of my model-making skills...) Here are some photos of it:

I am not quite sure but I think this last section rounds up the exhibition in the sense that it's protecting the past. The architectural model is actually a physical demonstration of the Mosaic Wall Preservation Project (President's Award in the Engineering Division); I mean it's a different approach to environmental design, but I think on a conceptual level of the exhibition it means that although we are moving forward we should always take a moment to look back and value the milestones that made us who we are today. This, also completes the circulation of the exhibition, connecting back to the starting point - the displays of the past.

Overall I quite enjoyed this exhibition even though it was rather short. But I think it made me think a lot in terms of value on a variety of levels. Hopefully I have described the virtual tour well!!

More to come: INSPIRED! Exhibition

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