Timothy Pan Portfolio

ROCKET 77

ROCKET 77

Engineered structure unites with a sci-fi shell in a celebration of cardboard’s unique structural properties - encapsulated in a futuristic, geometrically driven design.

Task: Design a beautiful cardboard stool that supports 180 pounds without deformation. No tape, glue, or other fasteners may be used. The entire stool must be cut out of a single sheet of 4x8ft C-flute cardboard with a maximum of four pieces. No laser cutting is permitted during ideation or production.

Contents:

Defining the Form

Optimization

Structural Theory

Working Prototype

Conclusion

Contents:

Defining the Form

Optimization

Structural Theory

Working Prototype

Conclusion

DEFINING THE FORM

Iteration Process:
As this assignment dealt with form as the driving factor behind my design, I began by sketching and prototyping with construction paper, and eventually moved onto scale models out of cardboard.

I understood at that time that cardboard was strongest when forming a rigid solid, and with complete solids I could utilize the net-making principles used by packaging designers. Although this was initially useful, eventually I needed to develop methods of my own.

Ultimately through critique and experience making scale models, the form concept was narrowed down to a single direction.

Iteration Process:
As this assignment dealt with form as the driving factor behind my design, I began by sketching
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CAD and Sheet Metal
A lot of my design workflow operates around the use of parametric CAD. In fall quarter, I invested a lot of time and energy into learning the Sheet Metal workspace for Solidworks which allowed me to prototype my stools virtually. This required no physical material cost and was significantly faster than working physically.

CAD and Sheet Metal
A lot of my design workflow operates around the use of parametric CAD. In fall quarter, I invested

The Pitfalls of Virtual Design
The risks of relying on CAD is that it is very simple to create a design that is simply too complex to manufacture. The earliest iterations of the stool had an incredibly sophisticated internal structure that was simply impossible to make tolerances for or cut out properly due to nothing being aligned with a grid.

Another concept had an attractive silhouette, but was so impractical to assemble that idea was abandoned.

The Pitfalls of Virtual Design
The risks of relying on CAD is that it is very simple to create a design that is simply too complex to manufacture. The earliest iterations

OPTIMIZATION

Now that the net was fully developed, optimizing folding and assembly became the primary challenge.
In order to make the stool properly fit together, many prototypes of the tabs and creasing order had to be created by hand. This was impossible to do virtually, but making countless models by hand taught me invaluable lessons about the properties of my medium that helped me significantly in the future.

Prototyping Best Practices

Due to instructor limitations, all prototypes had to be cut by hand. Due to the complexity of my net, this initially took quite some time, but I quickly developed several methods to speed up the process.

Two of the three parts of my stools could be traced from a paper template. The top cap, which had radial symmetry, needed to be drawn out completely by hand to ensure perfect accuracy.

Due to the difficulty drawing large numbers of angles accurately using a protractor, breaking every part of the stool down into simple x & y components that could be verified using a right angle became a necessity.

By writing the dimensions next to each line drawn, verification becomes a much simpler task.

Stress Testing
To test my model stools, I would load them until they deformed. Interestingly, I found a common failure point among multiple stools. Because the direction of applied force on the internal structure was against instead of with the bias, it would deform in this same place every time. Even very simple things like deciding which way I wanted to cut the cardboard had an impact on strength.

Stress Testing
To test my model stools, I would load them until they deformed. Interestingly, I found a common … See More

Ergonomics
Although the height and size of my stool were restricted by the maximum sheet of material I could use, I spent a lot of time measuring the height and seat size of multiple seating surfaces around campus to get a target size to aim for.

Ergonomics
Although the height and size of my stool were restricted by the maximum sheet of material I

Ergonomics
Although the height and size of my stool were restricted by the maximum sheet of material I

Tabs and Slots
The most difficult detail to perfect with the net was the tabs and slots. Finding the optimal dimensions for a joint that is rigid but still possible to assemble took many, many iterations, sometimes changing by miniscule values, and were somewhat beyond calculation. These parts could only be tested using guess-and-check.

Tabs and Slots
The most difficult detail to perfect with the net was the tabs and slots. Finding the optimal
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STRUCTURAL THEORY

Thinking like a Scientist
I like to approach finding solutions in a discovery-driven manner- If I generalize and articulate the knowledge I gain from observations, it makes it easier to not only extract concrete discoveries but to also share my findings with other designers who are approaching the same or similar problems.

Through this assignment, I developed a generalized cardboard strength theory through my own observations and observations of my peers. It revolved around three essential elements of a sturdy cardboard stool:

Thinking like a Scientist
I like to approach finding solutions in a discovery-driven manner- If I generalize and articulate the knowledge I gain from

Load Bearing Core
At least one uninterrupted piece of vertical cardboard being compressed perpendicular to its bais MUST run from the area of load application directly to the ground. This is the optimal way to put load on cardboard.

Elemental Interaction
The load bearing core should be held together using a method that is elemental and self-reinforcing- in other words, it should be the last thing to come apart if the stool is deconstructed and grows more involved as load is applied.

Rigid Superficial Detail
Any exterior detail must rigidly lock into the load bearing core and itself. This way, it not only serves its purpose as giving the stool an attractive form but also contributes to the load-bearing properties of the stool.

My Obsession
For two weeks during the most crucial iteration phase of my stool, I found myself consumed in my work. I held myself to a strict schedule and an unnegociable rule of 1 shower, 2 meals, 3 hours of other work, and 6 hours of rest every 24 hours. Even though the workload for this project was beyond anything I had ever done, I finished my project in good health with 4.0s in every class.

My Obsession
For two weeks during the most crucial iteration phase of my stool, I found myself consumed in

WORKING PROTOTYPE

Click here to see assembly video on Youtube

Click here to see assembly video

CONCLUSION

Why was this project important?
This assignment was an exciting chance to bring a form-focused design all the way from a concept to a working prototype. The process was long, rigorous, and tedious, but my obsessive fixation on pushing this design to its very limits paid off.

Alongside scoring a historic perfect 105% and the highest score in the class of 200, my stool was one of 6 to be displayed to the public and also the only one to remain in possession of the Design department as an example for future students.

Additionally, it was featured at the Seattle Art Book Fair and by Autodesk Instructables in the Paper and Cardboard Contest. I intend to continue producing obsessive, outstanding, and beautiful products in the future.