New structural options from everyday materials
In recent years, the boundary between art and engineering has continued to blur with scientists and researchers turning their formidable minds toward traditional craft techniques. The results are starting to get quite exciting, with surprise breakthroughs such as the Japanese origami-inspired ‘zippered tube’ featured above demonstrating that there is still much to learn about how we use familiar materials.
This example highlights a novel process of combining thin flexible sheets of material that have precise cuts and folds in them. The location and combination of these elements enables the material to become rigid when assembled in specific configurations, gaining structural integrity far beyond the original material’s capacity.
The research that developed this construction technique emerged from a collaboration between University of Illinois grad student Evgueni Filipov, Georgia Institute of Technology professor Glaucio Paulino and professor Tomohiro Tachi from the University of Tokyo.
“…we’re starting to see how it has potential for a lot of different fields of engineering” – Evgueni Filipov
Filipov and his colleagues focus on an origami technique known as Miura-ori folding, where a tube is constructed from two precisely folded ziz-zag strips. Individually, the strips are highly flexible but when combined the resulting tube has a remarkable rigidity and controllable degree of compression or folding.
What does this mean for Ponoko users? While much of the focus in the origami research is currently centered around potential uses in architecture and for space exploration; many of the options from the Ponoko Materials Library would be a great fit for this approach to assembly and construction.
Laser Cut Fashion
The intricate designs enabled by laser cut textiles are no longer an exclusive novelty for the haute couture runway scene. The bold fashion statements enabled by laser cutting are now within the grasp of the everyday consumer, with leather, silk and other textiles ideally suited to the digital manufacturing process.
Delicate patterns reminiscent of fine lace and needlework lend themselves well to laser cutting, but as we can see in the image above, bold shapes and iconic imagery can be just as effective.
With some clever design thinking, laser cutting has also enabled more exotic materials to become wearable garments. The wooden t-shirt below by Pauline Marcombe uses laser cut panels attached together with wire, transforming what was once a rigid material into a malleable interlocking form of modern body armour.
Why would you turn to laser cutting for brand promotion? For one, the eye-catching impact of these fashion items invites attention and a healthy curiosity… but also, thanks to the laser cutting process, there is much scope for design freedom and customization at a price that is accessible to the consumer.
How can your brand stand out amongst all the other fashonistas using the Ponoko Personal Factory? Let us know in the comments below. For more ideas for Agencies and Brands, see the other posts in the series.
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City of Bath Georgian House flat-pack model
Miniature models of local landmarks are a popular choice when it comes to souvenirs and keepsakes. In this example, the iconic Georgian terrace houses from the city of Bath in the UK are recreated with loving attention to detail.
Available as a flat-pack kit of three neatly stacked cosy homes, you can choose from either 1.5mm card or 3mm poplar ply, and the straightforward assembly process will only take a few minutes.
Ideal for Laser Cutting
Laser cut architectural models are the ideal choice to make use of tab-and-slot construction techniques that allow for quick and easy construction, often holding together without the need for glues or adhesives. Basic elevations of the structure can be traced out in your preferred drawing program (inkscape is a Ponoko favorite) and prepared for laser cutting. Take the guesswork out of designing with interlocking slots using one of several freely available tools and plugins. For a landmark or object with a more sculptural form, 3D models can also be sliced up into panels or interlocking sections that are just right to send to the laser cutter.
Optimise for Production (and add a little extra)
Once you have the profiles and parts that make up your object, arrange them neatly within one of the Ponoko laser cutting templates and add useful notes or assembly tips as etched details. The Ponoko guide to keeping laser cutting costs down contains important information that will save you time and money, so be sure to read through before starting to avoid common (and costly) pitfalls.
It can also be nice to add a little something extra to the assembled model. The Georgian terrace kits by Bob Kann come supplied with a little light to install inside, so that there is a warm welcoming glow that completes the homely feel.
via Bob Kann
Design resources that help you get started with laser cutting
The learning curve can be a steep one for some people when it comes to wrapping your head around digital manufacturing. Not only do you need to understand how to design for CNC, 3D printing or laser cutting; starting from scratch is daunting and design resources can be hard to come by.
In an attempt to de-mystify the process of digital manufacturing, Obrary takes inspiration from the changes enabled by the Open Source movement and has set up a resource supplying design files and code for anyone to use or improve on. Their motto is “Making it easy to make.” They do that by providing the Maker community with a library full of open designs and a series of eBooks full of information about the making process. The site has open designs from Makers from across the globe.
“Beyond improved sharing of design resources, new design approaches and engineering patterns are enabled”.
Users are encouraged to make their own tweaks to the designs, learning by trial and error in much the same way that made development for the Raspberry Pi so popular.
Have you ever wanted to build a cage gear mechanism? They’ve got one of those. How about an adding machine or even something simple like a robust shelving system… these are but a few of the designs that have been made freely available to the Obrary community. The design file package includes a number of file types including CAD files, interchange files (DXF, PDF, etc) and CAM files. So you should be able to find a file format that fits into your manufacturing process.
And one nice feature of the site is that all of their designs and eBooks have the same license – Creative Commons-BY-SA. This is a truly open license that even lets you sell products made from the designs.
“…making, building, and collaborating, not because we have to, or because it’s research, but because it’s so fun.”
Already a digital maker? Use the comments form below to tell us about other resources that were useful when you were just getting started, and how you’ve taken these skills and design adaptations into the Ponoko Personal Factory to turn them into reality.
See more collaborative designs and handy resources at Obrary.