Original Tutorial and Reflection

Google drive: Original PDF

https://drive.google.com/open?id=0B8eLSN6kq2-obkFOZ2FaT3VQYjg

Youtube Video:

https://youtu.be/qVtm0aPgl24

Compare and Reflection

(Top: my adhere. Bottom: adhere from another student)

I've focused more on the bump details and the curving edge compare to the previous adhere that is made from another student. I suggest that the sheet can be more detailed and delicate by achieving the the folds on the top part of the template and the round corners on the both sides of the shoulder.

(Top: my adhere. Bottom: adhere from another student)

I suggest to select smaller scaled tool (for all hammers and support tools) to achieve every single details on the adhere. Also, it might be good to break the shape into parts and beat it minimally with weaker force and repeat the steps over and over again, instead beating it with strong force and achieve the expected shape in one or two go. It takes longer process to do it my way, but it will creates more delicate adhere that matches with the template.

(Front: my adhere. Back: adhere from another student)

Moreover, I will suggest the discipline to include more details for the top part of the template. I seek it as the most important part that makes the adhere actually look like the selected object.

Metal Sheet Making

The waffle template provided from the student:

Metal sheet making: Day 1 

Place the waffle template on the aluminium sheet and mark the shape with 1 cm extension from the template. Trim the sides with metal cutting machine, then , use the scissor to cut the top part. 

Generally roll the aluminium sheet with the rolling machine to create a curve that allows the sheet to lay on the template. Mark the edge of the curve and start shaping with the shoulder of the PVC.

Carefully hammered the shoulder with small metal hammer. The area of curving is minimal, it is suggested to use smaller tool to create the shape.

Mark the exact shape of the cap and hammered the curve shape from the shoulder towards the top.

Continually shaping the outline of template by doing the above steps over and over again. Do not hammer it too hard at once, it is hard to push back the curve shape if it is sinked.

 

After curving the outline of the cap, hammer the sheet with bossing mallet from the opposite side to make sure the adhere is not sink in the centre. 

 

Result of day 1

Result of day 1

Metal sheet making: Day 2 

Starting to shape the edge of the adhere against to the special support tool with a flat surface plastic hammer. It is suggested to get a metallic support tool with long rounded shape to achieve continuously curving edge.

Make the side edges before the bottom, it allows the template to slide in to the incomplete adhere.

Check the parts that are unmatched and adjust the angle of curve carefully with smaller scale tool.

If you wish to bend the curve more: do not use the rolling machine, it will flatten everything you've done so far. Use the table side clip to pressure the adhere from the both sides to achieve the angle of curve you expected.

In order to make the bump details of top part template, you might need a costume support tool to beat against with. The supervisor makes a wooden tool with more narrow shape for me at this stage.

Image of the wooden support tool

By beating the adhere with wooden hammer against the special support tool, it creates two significant  bumps to match the template.

Result of day 2

Metal sheet making: Day 3 

 

Adjust the curve with the table clip on the side carefully. Do not over bend the adhere, it's going to be very difficult to get the shape back if it is over bended at this stage.

 

Cut the extras from the edge of the sheet with scissor. It is hard to achieve the curving edge of the adhere if there's too much extra on the sheet.

 

Soften the cutting edge from the above step

 

Place the template into the adhere and check if there are any parts that are undone or unmatched.

After fixing all edges from the top to the sides, close the bottom edge of the adhere with the same steps for doing the sides.

 

Finish the sheet by trimming the extras, soften the edges and match the outline of the template over and over again to make sure every lines and surface detail is completed.

Image of completed adhere

Image of completed adhere

Image of completed adhere

Image of completed adhere

Image of completed adhere

Assessment 2: Interdisciplinary Skin

Brief:

Create an aluminium skin to adhere to the contours of another students 3d template. Criteria is based on the metal shaping, documentation and reflection. 



Object from another student:

The exchange object is PVC glue from the architecture disciplinary. The above image is the completed adhere and template from another student. 

Step 7: Create Aluminium Adhere

The shape of brick can be seen as a cube with extensions. After discuss with the lecturer, I decided to make two separated aluminium adhere to show both detail on the top face and side.

The actual object and the 3D template

The Top Adhere:

The shape of the top surface is formed with two significant negative space. Instead of getting a ruler and measure how much aluminium sheet I need for my adhere, getting a thin strip folded into the shape would be easier.

The dimension of the unfold strip is the length I cut my aluminium sheet.

After knowing the measurement from the stripe, I manually cut the 1mm aluminium sheet into a smaller piece (slightly bigger than the area I need)













Roughly fold the sheet with the shape of the shape done previously. The shape needs to be constructed from the middle to the side. It will be impossible to use the folding machine if the process goes from one side to another. 


Slightly smoothen the folded bit by hammering the sharp edge. (Do not band the aluminium sheet from both side or re-band the same area over and over agin, the sheet may crack) 








Find a metal tool that's similar to the size of the negative space and giving force from the top by hammering to the aluminium sheet. 


This process allows the sheet to be more obedient to the shape of the template, also adjust the size of the curves. 















Completed adhere for the top surface of the template














The Side Adhere:
(first attempt)









Cut the aluminium sheet into suitable size for the object


















Measure and mark the four holes on the template. Roughly hammered the negative space against a sandbag.















The negative spaces are unsymmetrical with sloping surface deep in the hole. In order to achieve the shape perfectly, you are required to make a special tool to hammer against with. (ask the supervisor for help when using the tool making machine)














The special made tool.



Place the tool under the spot you wish to be deeper on the sheet and beat around it with a metallic hammer. (the reason for choosing metallic hammer is to shorten the time making extreme shape in shall surface)
















Front view of the hole



















Back view of the hole
















The special tool helps to achieve the shape quickly, but you need to hammer the shape carefully. In this case, the aluminium sheet was cracked by pushing the shape too hard in one go.


I decided to make another adhere. The place where it cracks is hard to be pushed any further.














(second attempt)

Cut the aluminium sheet in suitable size for the side surface (needs to be slightly bigger then than the actual size, the sheet ill shrink while making the negative spaces in the center)



Mark the four negative space with black marker and hammer the shape with a rounded tool over the sandbag (needs to place on something soft to allows the sheet to bend)









Cut the top edge with two "u" shape to fit the surface of the template. 


Mark the edge of the two sides and manually band the extra sheet into 90 degree angle (this also helps the adhere to attach to the template)
















Smoothen the top and bottom edges with equipment.













Attach adhere to the 3D template, fixed the lumpy surface with hammer that contains a flat metal side. 


Also push the sheet harder to show more details of the negative space (the adhere can be beaten over the template carefully with a wooden hammer)


You can use the special tool made in the first attempt, but don't try to achieve the shape in one go, the aluminium might crack again.










Completed adhere for the side surface of the template

Check the side of the model to see if the aluminum adhere fits to the template