JAKE

JAKE

Research and Experimentation

I decide that it would be interesting to continue with this process as I though of many interventions that really interested and that i thought could go far with.

I wasa first fascinated by iron-on veneer or edging that carpenters use to make plywood or MDF look like solid wood. I thought about why they don't use this process when making bentwood lamination forms. While they use huge moulds requiring even bigger presses and then a setting time of multiple days, they could instead use this method

This method requires special glue that is thermo-setting, but I really wanted to see if I could work it out with plain old wood glue.

i found the website below quite informative about one process that I could try.

I started experimenting by looking at what temperature dried PVA becomes liquid againby putting a sample in the oven, but all that seemed to happen is that the glue would get a little sticky and then burn.

I then tried glueing wood strips, letting it dry, then using a hot iron to bond the pieces of wood together.

I was very satisfied with these tests and the speed of the results. I think in future I could experiment with speed, temperature, pressure etc...

Here are some of my first tests.

After this, i got more ambitious with the tests, In the test below I spread glue on five thin pieces of veneer. I let the glue dry, then using an iron I glued certain areas in order to get this natural flowing shape.

To spread the veneer apart I added some bolts.

I then talked to Daen for a while and we came up with the idea of using bolts in offset holes to curve the veneer.

Testing the machine

I tested the machine that I made with some 3 0.8mm thick pieces of beech veneer. I heated the element up to around 200degrees and coated each individual piece of veneer in wood glue on both sides.

I set the rollers to an appropriate width to ensure that the veneer would be pressed evenly together.

I pulled the veneer through the machine ensuring that I allowed the glue to dry as it exited the rollers.

The first few bends worked for the first 20cm but afterwards, began to stick before goilg through the rollers creating an open space between the veneer.

I noticed from one of my failed tests that the area where the veneer seperated created an interesting hinge-like effect.

I followed this up by drawing a few of the joints that I could think of that could work.

Below are some of the tests that I made based on these sketches

RECAP

At this stage of the project, I am beginning to get slightly confused over the direction of where I want to head.

Do I focus on the aesthetic of the structure or do I focus more on the movement that this aesthetic form creates.

I believe the motion is the more interesting part of this project, Is has more possibilities, and there is still the inherent visual beauty of the pieces.

I will continue to exp[eriment with types of motion created by wood veneer.

But first, I needed to find a way to get veneer in a cheap way and I found a way at home using one of my tools to cut off thin slices of wood to create veneer to test with.

I tested using other methods to create curved bentwood lamination that don't use the use of an unwieldy and time intensive mold.

I used ratchet straps.

I also tried bolts.

I then tried wetting one side of a piece of veneer to see how it would deform.

I then sought out some inspiration on compliant mechanisms as I thought that this would suit my project fittingly.

I came across an interesting company making flexible airplane wings, but apart from this they also had many interesting examples of compliance.

INSPIRATION

I did some more research into the matter and came across Dr. Larry Howell who is the father of Compliant mechanisms. I watched videos read extracts from his books

In the book Covell writes that compliant mechanisms have been around for as long as we look back. Compliancy is found in nature in many cases, and as seen above, in the wing of a bee.

He also writes of the advantages of compliancy. Less material wastage, faster production times, increased performance to name a few.

As I have been reading his material and looking at examples of his work, I am beginning to notice how influential his work is and could be.

I notice that there are already a lot of use cases in medical, aerospace, and mechanical applications but other than that this beautiful process is generally unknown to the wider audience.

I would really enjoy seeing how far I could take a concept like this through the eyes of a product designer, subsequently showing it off in a beautiful way and giving attention to this complex process that could revolutionise our world.

Microscopic compliant Mechanism

Rocket thrust vectoring compliant mechanism

I began to experiment with compliant mechanisms and specifically Bi-Stable Mechanisms.

Concurrrently, I looked into ideas for products that I could use to test my creations.

My first idea was a lightswitch, but hopefully in the end I have a more visually appealing product, but this serves its purpose as a test.

After these tests, I took a break to contemplate over what the possibilites. As the teachers liked how I brought technical issues or fascinations of mine into abstraction, I thought that I would like to take that route.

I like the direction that I am heading, but the experiments that I am doing are still not expressive enough or demonstrative of the motion that I am trying to convey.

I decided that i would experiment more with making compliant mechanisms that I thought had an interesting motion.

I continued with testing the bi-stable idea by making a coat rack that utilises the feature.

I laser cut the sections I needed to create the structure, then glued the cut out veneer to the laser cut parts.

RECAP

I tried experimenting with paper but immediately changed to experimenting directly with veneer.

I found that the above motion complimented the veneer well and created quite a natural movement.

I liked the simplicity of this 1/10 scale model. The simplicity of the motion is pleasing, but I was not sure whether it was enough of a showcase of the project.

I decided to then create a more visually obvious implementation of compliant mechanisms by imitating old rocking chairs in a modern style.
I tried to create the chair as methodically as I could to figure out if I could produce this at full scale.

I produced it in 1:5 scale and laser cut moulds for the seperate parts.

Looking back on my latest models I had some thoughts:

I believe that these are all pretty interesting routes that I could take, but I feel that I am not taking advantage of the idea that I am trying to peddle. Every time I implement it, it is through slightly adjusting already existing objects. At the same time, this adds a level of complexity not seen in the original design that may not be so pleasing to the eye.

It is clear that I need to implement this in a more full circle way. I need to think bigger. I need to stop looking at the pre-existing and try to start from scratch.

I liked the simplicity of this 1/10 scale model. The simplicity of the motion is pleasing, but I was not sure whether it was enough of a showcase of the project.

I decided to then create a more visually obvious implementation of compliant mechanisms by imitating old rocking chairs in a modern style.
I tried to create the chair as methodically as I could to figure out if I could produce this at full scale.

I produced it in 1:5 scale and laser cut moulds for the seperate parts.

Next, I was excited to see if I could make a compliant bi-stable hinge from veneer.

This interests me as it could be an elegant solution to over-complex mechanical hinges in the future.

Below is a sketch of what I believe the hinge could look like.

I created a fixture with a board with holes, dowels and 3d printed parts in order to test various positions.

Below is a test video and a sketch of how the hinge could be implemented.

RECAP

JAKE

I started with a 3d print. It was a good first try, but not a good enough representation of the flexibility of veneer.

following this I made various models in different scales with thick card, paper, plywood, and veneer.

After a lot more work, I had created a parametric model in fusion where I could mess around with all of the dimensions easily.

Once I decided on the dimensions I had to buy enough veneer to make the chair.

I then cut out the mold for the chair on the CNC, It was important that the mold was perfect, as it was what would form the chair.