Two materials and a weird fastener

This week’s assignment was to joint two different materials by using a fastener, I decided to work with pine and with cork in order to generate a shape around a central axis.

 Materials and cuts

Materials and cuts

I started by drawing the shapes in both materials and cutting them with an utility knife in the case of the cork and with the band saw and sanding in the case of the wooden base. Y also made a hole in the middle of each one of the pieces in order to use this weird fastener that I found in the shop, which has two different levels.

 Stacking layers of cork

Stacking layers of cork

 Cutting the wooden base

Cutting the wooden base

I used the first level to screw into the wood and the second level to joint the 5 layers of cork that I have previously cut. Once they were all together I screw together the two separate levels in order to generate a concentric shape of two different materials.

 Assembly process

Assembly process

The final result is the union of two different materials by using a mechanical joint, which can be de assembled in order to take all the pieces apart and the shape is intent to simulate elements of the nature such as as flowers.

 Final result side view

Final result side view

 Final Result side view

Final Result side view

36 out of 100 women enclosure

For this week’s assignment I decided to work on my final project for ICM/ Pcomp and build an enclosure for it, the fabrication part of the project I need to create 36 holes to embed 36 female inputs for an audio jack. I decided to build a wooden frame with tick solid wood and to laser cut the cover that would have the holes on it.

 First sketch of enclosure

First sketch of enclosure

I started by cutting 45 degree angles on my recycled wood, I measured the sides and tried to calculate very well measured angles so that I could then ensemble them as a frame.

Cutting the wooden frame

I was able to fabricate 4 pieces with 45 degrees. I developed the first test of the cover in recycled pre painted wood, however since it was bend I had to create a second piece changing the material for a flatter one so that the laser cutter would work in a better way.

 Assembly of the frame

Assembly of the frame

I ensemble the four pieces of wood together with L shape mechanical drilled joints to ensure the stability of the structure.

 L shape internal support to hold together the frame

L shape internal support to hold together the frame

 Finalized wooden frame

Finalized wooden frame

The second test of the cover was developed in the laser cutter, I edged the numbers and the circles that do not need a hole and I also included in the Illustrator file the cut of the circles for the female inputs and the holes for the screws so that I could ensemble the cover to the frame in a very robust way.

 Laser cutting second version of the top

Laser cutting second version of the top

 Drilling holes to support the top to the frame

Drilling holes to support the top to the frame

The final step consisted in putting together all the 36 female inputs for the audio jack on with the cover laser cutter piece.

 Placing the 36 inputs

Placing the 36 inputs

 Placing the 36 inputs

Placing the 36 inputs

 Final enclosure in the back

Final enclosure in the back

The final result is an enclosure that will be used for my final ICM and Pcomp project, the fabrication was made in a very robust and strong way thinking in advance about the user interaction and the manipulation that they might give to my piece. Since the audio jack will be changed from one female input to another multiple times, I needed to make sure that the structure and functionality of the piece remain good throw the entire time that it is going to be displayed to the users.

 Final enclosure design

Final enclosure design

Five imperfect necklace holders

This week’s assignment consist of repetition: Fabricating “5 of the same”. The ideation process started with a quick benchmark research of simple projects for beginners in the treatment of wood, because since the assignment was announced in the class I knew I wanted to work with that material. I also knew I wanted to create something useful and that I could hopefully give away to my friends.

Read More

Wearable Flashlight

For the first week of the class I received the assignment of doing a flashlight with the only two following requirements": It has to be portable and it has to create light. As soon as I heard the word “portable” I transformed it into wearable and I started doing some research on options about how to create a flashlight that could be used in order to solve an specific problem.

While doing a benchmark research I decided to focus my ideation process on creating a necklace that produced light, I found some ideas that helped me shape the product. I also created a moodboard in order to define the use cases and the look and feel of the flashlight.

 Moodboard for flashlight

Moodboard for flashlight

The next phase of the process was to define the materials to use, I wanted my flashlight to not only generate light from the “front” but only from the sides, therefore I knew Acrylic would be the better option in order to create what I was planning. I also decided to work with “layers” of acrylic to that when the LED would be on, some light would come out from the sides but not in an homogenous way, and instead it would create a line pattern.

 Ideation and sketching process

Ideation and sketching process

I decided to use a coin battery in order to be able to create a small flashlight that could be worn around the neck, this represented a huge challenge since I had to soldier all the components very close to each other. I use a toggle switch that decided to put in the bottom of the flashlight and a blue LED attached to an LED holder. I faced a lot of challenges while trying to make the light work due to the battery, since I have never worked with them before. The final process of the soldiering and testing looked like this.

 Circuit with lighted LED controlled by toggle switch.

Circuit with lighted LED controlled by toggle switch.

For the fabrication process I decided to create rings in Illustrator in order to generate a cylindric shape that would have the components inside, the button of the flashlight has a rectangular hole for inserting the toggle, also I left space for inserting a necklace from the sides and the top of the flashlight contains the light which is confined also by an internal circle piece with a hole so that the top of the LED could come out and at the end I finished with one last full circle of acrylic in a with fluorescent film on top.

I had to ensemble all the rings one by one and make sure that they were aligned and forming the desirable shape, at the same time the placement of the component represented a challenge due to the change in the diameter of the rings, therefore I had to make sure that at the end all the components would fit once I closed the flashlight.

 Laser cutting the rings

Laser cutting the rings

 Assembly of the rings with the components inside

Assembly of the rings with the components inside

 Components inside the flashlight

Components inside the flashlight

 Interior with exposed LED

Interior with exposed LED

The final result is a flashlight that can be worn as a necklace therefore the light can be generated wherever the user is. The biggest challenges of this project were trying to align the rings at the same time of keeping the components inside the cylinder and specially having to understand how to use small components in order to create a wearable device.

 Final result: Flashlight

Final result: Flashlight

 Flashlight / necklace

Flashlight / necklace