PRACTICAL 3
Practical 3: Cardboard Joinery 📦
This week we were introduced to the different ways to join pieces of cardboard ✂ together. However, before we could do so we had to understand 🤔its properties, composition, and the different types of cardboard and how to handle it.👷
SHORT NOTES ON CARDBOARD 📔:
Our pre-session preparation was to research 💻 about cardboard, this is what we found 😎:
Cardboard also known as corrugated board gates is made out of 3 components, in this order:
1. 1 layer of paper as the inner liner
2. A sheet of corrugated material - placed in the middle to increase its rigidity and stability
3. 1 layer of paper as the outer liner
Two main types of paper used from manufacturing are : Krafts and Tests - due to their strengths💪 and cost🤑.
Krafts are strong and easy to print on, which is why it is used as the outer liner.
Kraft
Tests are cheaper and recyclable but not as strong or easy to print on. Therefore it is most commonly used for the inside layer.
Tests
When we are choosing the type of paper to use or designing ✂📐🔧 a prototype📦 using cardboard. it is important to consider the weights of the paper. Most commonly, the weight of the paper is 115/125 GSM.
Also, the wall type is an important factor that affects rigidity. With more layers "fluting sections" present, the more rigid the cardboard is. There are different types of flutes which such as the “EB” flute which can be used to improve rigidity and strength of cardboard.
Types of flutes:
The corrugated section types i.e. flute types, vary from fine flutes like ‘E’ for lightweight cartons to coarse flutes like ‘B’ for transit packaging. Combining 🙌 is possible for the best of both worlds i.e. it is strong yet appealing visually: ‘EB’. Basically, parameters like weight, flute type and number of walls can be varied to achieve different grades of cardboard with variety of performance. The typical flute weight used is 105 GSM (grams per square meter).
Normal cardboard without any additon:
After adding 1 layer ' "SINGLE WALL"
After adding 2 layers 'TRIPLE WALLED'
Board grade naming , is used to describe the cardboard and generally the naming comvention is outer layer follow by flute type and inner layer. For example, 125 GSM Kraft, 125 GSM Test and B fluting are 125K/B/125T.
WHY USE CARDBOARD?
- Easily available (Cheap) 🤑
- Sturdy 💪
- recycable ♼🌱
- easy to manipulate 🔨🔧🔩
The whole point of practical 3 was to introduce us to the idea of prototyping and its advantages and joinery is a huge part of prototyping...
📌WHAT IS PROTOTYPING?
A prototype is an early sample, model, or release of a product built to test a concept or process. A prototype is generally used to evaluate a new design to enhance precision by system analysts and users.
👍👍ADVANTAGES OF PROTOTYPING
- Fail early and inexpensively
- Gather more accurate requirements
- Technically understand the problem i.e. By developing a functional prototype, one is forced to address both the foreseen and unforeseen technical challenges of a device’s design.
- Conflict resolution i.e By taking advantage of rapid prototyping, one can conduct several different iterations of the feature and benchmark the resulting performance to analyze the trade-offs of each approach which can save time.
- Increases Feasibility
Actual experiment work 🔨
As a group, we had to produce a visual board 🔤 showing as many different ways to join cardboard together as possible. First, our lecturer taught us the different ways to join cardboard together as possible. Some of the ways he taught us were:
1. Flange
2. Slots
3. Holes
4. Zip ties
5. Skewer
6. Score bend
7. Gusset
8. Tabs
Here is a video we referred to that demonstrated how to make these joints. We were also given samples to observe how to make them.
However, we also had to make sure we cut the cardboard safely. Here's a video we referred to from which we followed suit:
1. Thumbtacks i.e paper fasterners
2. Cutting mat
3. Glue Gun
4. Pen knife
5. Ruler
6. Cardboard
Here are some videos we recorded of the construction process for the different joineries:
Score and Bend video:
Slots and Tabs Video: https://drive.google.com/file/d/1VuKRgUFXY7-hU5nU9vtXjS68hphtYMQG/view?usp=sharing
Gluing process:
FINISHED PRODUCT!
PRESENTATION:
We chose the TABS + SLOTS joinery as our most preferred joinery because it was the most difficult to make as it involved alot of cuts, internal cuts and alot of precision if not the tabs would not fit. But we still chose this joinery because we felt a sense of achievement after being able to successfully make it and that too - visually appealing as the edges were clean and fit like a glove.
Reflections:
During the process, we did come across a few challenges as this was our first time working with cardboard. We were very slow compared to the other groups and even made a few mistakes at first, but we eventually delivered the visual board. It was very fun to do as it was a refresher from normal conventional chemical processes or product. We also realised that the cardboard is easier to cut in the direction perpendicular to the squigly lines of the cardboard. Which made our later joineries easier to make than when we were making the first few. Overall it was a great learning experience and we cant wait to put this into application for Practical 4 - Toy making.
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My Little Assignment
After being introduced and having experienced the various types of joinery as a group earlier, now we were tasked to create a winged unicorn from the template given which was created by Mr Bartholomew Ting, a graduate from NUS Business School who landed in management position of a MNC & soon gravitated to creative arts. He designed exhibition booths for years and finally realising his true passion as a cardboard sculptor. As we followed the instructional video we managed to create the unicorn see our various documentations below!
Little Assignment: Serena
This was my process of assembling the unicorn:
The template
Step 1: I removed the various parts from the template
Step 2: Following the instructional video, i constructed the head
Step 5: I assembled the 3 parts plus the tail!
Final Product:
Behold.. THE UNICORN! (front view)
Side View of Unicorn
Time lapse video of construction:
From the process of building the unicorn, I observed some joinery used.
1. Folds, particularly - tuck
fold where one part of the piece would be tuck into another to form the desired
shape and to keep the pieces together.
Then, we were instructed to make a mechanism so that the wings return to its starting position. This is what I did:
Item(s) used:
- 2 Rubber bands
Step 1: Hold the inside of the wings so that the gaps on the tabs are aligned.
Step 2: tie the rubber band to the interlapping portion of the wings' tabs
Step 3: Attach another rubber band (orange) to the 1st rubber band (in step 2).
Step 4: For the wings to flap, pull the rubber band backwards.
Below is a video and boomerang to show the process:
Lastly, we were assigned to sketch a mechanism that will automate the wings of the unicorn flapping. Below is my sketch:
MECHANISM: there will be a motion sensor on each of the outer surface of the wings of the unicorn. Every time it senses a person or their hands nearby, the sensor will be activated and it will move the wings however the extent of movement will not be "flapped enough" or to ensure that both wings do flap simultaneously, there will be 2 gears connected inwards on the surface of each wing which will be connected by a string when the sensor is activated and moves a wing, the gears connected to the wing will rotate, thus turning the string connected to the gear and will in turn cause the other gear connected inward to the other wing to rotate thus moving the other wing. This mechanism not only conserves the battery life of the sensor as it only is activated when motion is detected but it also ensures the proper automation of "flapping" of the wings not just unsynchronised movement of the wings. The idea is inspired by motion-sensing moving cameras.
Little assignment: Kai Rong
This is the assembling process of my winged unicorn.
Firstly, I took out each part and lay them out.
Next, I assembled the 2 main
parts, the body and the head.
Lastly, I put together the 2 main
parts and then attached the wings and this is my final product.
While assembling the winged
unicorn, I observed the types of folds and joints used.
The main folds used is the tuck
fold where one part of the piece would be tuck into another to form the desired
shape and to keep the pieces together.
The main joints used is sloth and
tabs to attach the wings and tail to the body.
Next to make the wings flap.
What I did was to tie the two
wings together using a knot using a rubber band.
Then I pulled the rubber band
through the gap between the head and the body.
This is how it looks like in
action.
To automate the wing flapping.
A wheel would be place between
the 2 wings where the small block will push the wings forward when the handle
is turn and naturally fall back in the original position. This cycle repeats
which creates a automated wing flapping system.
Little assignment: Kenny
This is how I assemble my unicorn
Step 1: I assembled the body
Step 3: I assembled the unicorn as a whole
While assembling, I observed that L-brace and slot is being used.
While assembling, I observed that L-brace and slot is being used.
To automate the wing flapping,
I glued the intersection part of the wing the a rubber band as as to control the movement of the rubber band.
Little Assignment: Jerome
1.
During the assembly of the unicorn, the most
noticeable types of fold and joints are slots and tabs, and L-Brace.
2.
Assembly process
A.
Carefully take out all the carboard pieces from
the cardboard
B.
Assemble the body of the unicorn by slotting all
the tabs into the correct slots like so,
Once properly assembled a body will form like so,
C.
After assembling the body, assemble the head
like so,
D.
Finally attach the head, body, and wings.
3.
By using rubber band and more cardboard I can
make a rotary mechanism which consist of a wheel that spins and will make the
wings move.
4.
The wings will be together with a rubber band and the rubber
band will be glued to the cardboard rod. The cardboard rod will have a notch
that is connected to a wheel that can be spun to move the wings of the unicorn.
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