Inspired by Sand dunes formation and its patterns.

Performance
Horizontal Roughing was important to be done prior to the 3-axis Projection Pocketing in order to save time.
The whole process in total took 1 hour.

3D milling – Process consisted of two phases:

First phase:
horizontal roughing
Tool: BallMill 26mm in diameter
Dimensions of the board: 600 by 400mm
Boards of 8mm thickness
Time taken: 9 min.

Second phase:
Projection Pocketing following a rectangular path
Tool: Ballmill 12mm in diameter
Global parameters intol: 0 , outtol: 0.4,
% Tool Diameter: 25 %
Time taken: 48 minutes

Rhino file: steps of formation

Horizontal roughing

Digital Fabrication final output ::: Lamp

Material

We were assigned the bending technique using Paper/Cardboard. In our preliminary 3d model manual sketching we used 80g/sqm A4 sized papers. We wanted to design a lamp that is composed of several small units that interlocks and curves in more than one direction. We finally arrived to 0.6mm thick cardboard as it is not too thick in order to easily bend it in small scaled units and neither is it too thin in order to retain its curvature after bending.

Units' formation

Geometry

Initially, we were trying to apply the concept of the geodesic dome, but using random units by which all the small units work together to form the whole. The challenge was how to create a random pattern of units of the same family or language (originating from a grid) so that together the units composes a lamp that it is viewed differently from different angles and dropping different shadowing effects.  Through our research, we found an interlocking connection, that we then developed  to assemble our units together. This connection end was then copied and mirrored and rotated along the 360 degrees one every 45 degrees,  in order for us to have a polar grid of 8 connection ends. From this grid we linked the connection ends by curvilinear lines, creating different formations of two, three, four and five sided versions of the same language.

Units - Grouping - Idea of engraving

Group19: GOKUL RAJ KAILASH, HUNIA TAREK TOMOUM, YAPING CHEN