Chris Pappas - Digital Construction

1. Bowl Task
2. Torus Task
3. Blister Task
4. Tray Task
5. Fuel Tank
6. Individual Reflection

1. Bowl task

2. Torus Task

3. Blister Task

4. Tray Task

5. Fuel Tank Assignment

Individual Part

Before we begin the individual section of the tank, we considered 3 different options to choose from and the team decided to construct the peanut tank. We them obtained  rough dimensions and measurements in order to create a 3D model using Auto Desk Slicer, we were required to use the laser cutting machine to cut the templates. Furthermore, once the model was built, we joined all the pieces together however realised it seemed loose and needed to be sturdy in order reflect this onto our metal pieces. To rectify this issue, we used the hot glue gun which held the template together.

Autodesk Slicer 3D Model

 

 

 

 



Laser Cutting Machine

 

 

 

Templates Assembled

 

 

 

Glue Gun used to hold template together

 

 

 



The individual part of the tank allowed teams to be formed within the group to work on separate section of the fuel tank. I chose to construct the right side of the tank. To commence, I cut a rough side of aluminium so I could properly shape my side of the tank to.

I then drew circles on the aluminium like in the previous task where I constructed a bowl. Using this method allowed me to stretch the piece in the direction I wanted.

Also using the English wheel again allowed me to stretch the piece and curve it.

After the section has taken shape, in order to curve the top edges to the mould I used the mallet to do so. The image above illustrates this, drawing lines to target these areas.

 

 

The below photos are the finished product of my right section of the fuel tank.

Finish Product

After constructing 3 different sections of the fuel tank, the finished product was finalised and each piece of the tank was carefully joined together. As reflected by the photos below, the edges of each piece align with each other allowing a smooth and continuous run along the perimeter of the tank.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Individual Reflection

For the individual reflection, I chose the tray task as it revealed some strengths and weaknesses in my ability to construct it. The assessment of the tray was basically on our ability to shape and form metal sheets into a small tray and joining them.

The first step involved using the laser cutter to create the template. The template allowed us to choose what radius we wanted to use in order to construct the tray. The smallest radius would be the hardest to shape the corners however would reveal a better quality finish. This concept would in time reveal to be quiet difficult.

Laser Cutting Machine making radius for tray

 

 

After choosing the smallest radius for our tray, we had to shape our 2 pieces of timber using the radius in order to make a template for the tray. We used the sander to shape the template. This step was very important as it acted as a guide to obtain the ideal shape of the tray. This area of constructing the template was a strength as it made it easier to build the tray.

 

 

 



Shaping the edges on the template using the sander



The following step was to mark out the template using a metal sheet. To shape the metal sheet with dimensions we measured, we used the guillotine to successfully mark out the edges. We then clamped the sheet to remove excess metal as the guillotine couldn't cut finely in tight areas. This process was also difficult as we didn't want to remove too much excess metal as it would be extremely hard to curves the edges. In addition once you take of too much metal, you will need to start again therefore my partner and I only removed approximately 1-2 mm of excess metal. These edges were sanded lightly then again clamped between the 2 timber templates in order to curve the metal edges and begin the metal work process on the actual tray.

 

 

 

 

Marking out dimensions using timber template



 

The most difficult process that was revealed whilst constructing the trays was shaping and curving the edges. Using the mallet allowed me to make strategic hits to the edges however struggled due to stretching and expanding the corners. Instead of hitting one corner, I changed my plan so that I would hit both sides of the metal sheet and would work my way into each corner. These strategic hit were not hard at all but only with enough pressure to achieve what needed to be accomplished. Only one of the corners of the tray was properly curved, therefore in order to rectify this issue, I used aviation snips to tidy the corners then further used a plenish hammer and dolly to smooth the corners. This strategic solution to fix the other 3 corners worked then I used sandpaper to achieve a higher quality finish on all corners.

 

 

Constructing the tray posed some difficulties, especially issues regarding shaping corners however with carefully placed hits and new strategies to overcome these issues, the finished product was not too bad at all. Below are photos of the tray my partner and I created.