REFLECTION ON PROCESS OF METAL SHAPING

Devices use for digital making process

Smartphone

Laptop 

Camera

Software to download 

123D catch by Autodesk ( on smartphone ) either from App Store or Google Play for free

123D make by Autodesk ( on laptop )

Meshmixer ( on laptop )
Adobe Illustrator ( on laptop)

Tips and tricks on using software

123D catch

Avoid choosing objects with plain, reflective or transparent surfaces.

Draw different texture or color on mono colored object allows 123D catch app to capture the accurate shape of the object.

The object must remain still when taking a photographs with 123D catch app.

Try to take as much photos as you can from different angles to get 3D model generate smoothly.

Meshmixer

Clean up the excess surfaces of 3D model in meshmixer is important because we want 3D model to replicate the accurate contour of the object.

123D make
123D make can generate the templates to assemble 3D model through different construction methods depending on the material choice and thickness. Some object can only assemble through certain construction method and always good to choose the construction method that can replicate the form of object.

Adobe Illustrator 
The templates from 123D make upload to the Illustrator to change the outlines of the templates, red line indicate to cut through and blue lines are for engraving. Stroke weight needs to be changed to 0.0001 mm for successful cut.

Tips and tricks on laser cutting process
Laser machines should only operate by someone who trained to use machines. Carefully select the plywood and other wood sheets because bend plywood sheets tend not having successful cut.
After upload the templates on the laser-cutting lab computers, modify the printer settings according to the material( sheet) and check with laser focus tool to make sure that laser focus remain inside the sheet edges for successful cut. Don't forget to turn on the air filtration and wise to wear the mask due to the strong fumes produced from laser cutter. Assemble 3D model according to engrave numbers on templates.

Machines and tools for metal shaping
Guillotine ( to cut larger piece of metal)
Pan Brake ( to fold the metal sheet)
Roller ( to roll and curve the metal sheet)
English wheel ( to smooth out the metal skin)
Steel ruler
Tape measures
Scribes/ knife
Marking pen
Tin snip
Aviation shears
Hammers
Wooden mallets
Sand bags
Stakes/ dollie

Tips and tricks on metal shaping process
Machines and tools in the workshop should operate carefully due to safety.

Consult with the tutors in the workshop on how to approach to get the desire metal skin which contour nicely to 3D model and make a plan. Might not turns out exactly as the plan but can learn from the mistakes and failures. If you see someone who is doing well with their metal skin, ask them how they shape and what tools they use to get the desire shape. Always good to check regularly with 3D model as a reference because once the sheet was bent to a certain level, it is too difficult to bring it back. Try to stick with appropriate scale for 3D model, avoid large scale 3D model if you have limited time frame for metal shaping. Because the bigger the 3D model, the bigger area to contour with metal sheet and need more time to spend in the workshop. The more details show on 3D model, the more detail you need to contour on the metal skin. 

Interlocking 3D models work better for object with curved shape with not a lot of detail, where stacking 3D models work better for object with complex shape detail that can hammer on it directly to get the detail contour of 3D model. If your 3D model has complex shape, just try to shape the portion that shows just right amount of curves and details unless you have time because metal shaping is time and energy consuming process. I learnt this through my own metal shaping experiences, for my first skin I got Polaroid camera as my 3D model and it has complex shape. I tried to shape the whole 3D model with metal sheet and was a mistake because the skin turns out with a bit rough finish even though I spent a lot time and energy. If I cover only half of 3D model, I can polish the skin much more in details without wasting too much time and energy. But this kind of failure is precious because I can learn so much from the mistakes. I find my metal shaping process is so much easier second time around because I gain more experiences after the first metal skin and took an advice from Mathew ( landscape architecture student). 

The longer time spending in the workshop, the more familiar with the tools and easier to shape the metal sheet. Experimenting with different tools is crucial because only with the right tools, the desire result can be achieve. Helping each other in the workshop and taking turns to use the tools is fun part of working in the workshop. Important thing I learnt from this metal shaping experience was that working together with students from other discipline allow me to look at the things and obstacles from different perspectives.