Designs are getting sophisticated enough at Super-Releaser that it’s time to gather some data. One of our designs, an inflatable arm cuff, needs to move about 20 foot pounds (or pound foots) of torque to be able to overcome the spastic muscle contractions it’s expected to experience.
Long time no see, folks. I’ve got some great news for you. I’ve finally found a method for getting super complicated geometry locked inside of a seamless skin. It’s taken a lot of prototypes to get here, but I think the results are more than worth the effort. There are some wrinkles to iron out (which I’ll get to below) but all in all I think I’m incredibly close to rapid-fire casting working quadrupeds, ready to go in just a few short steps after popping the mold. In other good news, I’ll be dropping some files very soon which should get you your very own working quadruped using any FDM printer. All you need is a Makerbot or similar, a few hours, and some casting materials to have an exact duplicate of my most sophisticated robot to date.
I’ve been working on this project for a few months, focused on changing how soft robots get designed and made. Traditionally these robots are complex to design and build, and they require and unexpectedly large amount of hand labor to stitch together. This ends up with parts being produced slowly, with small deviations from known working designs. I’ve been trying to come up with a method that allows you to design a robot in CAD, queue up the design on a powder printer, cast silicone into the printed mold, and pull out a working robot. The idea is to allow for a huge variety of geometry, experimentation, and prototypes that are quick and inexpensive to produce. I want to make the process a whole lot more like a scientific experiment, where you test and observe multiple samples while adjusting a single variable. Continue reading
A few months ago I was commissioned to restore a storefront over on 5th and 32nd st, JJ Hat Center. They’re long time clients, partners of the good folks over at Pork Pie Hatters. I’ve done a lot of work for them over the years, building their website, designing custom hat blocks, making marketing materials, and creating the branding for their series of handmade hats. This was a whole other level of project, though.
To start, the building used to be an IBM adding machine factory and showroom. When JJ’s took it over, they installed a lovely wood exterior. So, on the plus side, there is a lot of old NYC richness both inside and out. On the downside, the wood exterior had fallen apart in the intervening years. Part of my job was to see through the decades of wear and tear and come up with a plan for refurbishing everything to resemble the original without spending thousands on custom parts. Fortunately my friend Clark put me in touch with a few very talented carpenters. So, with some meetings and design drawings, they were rolling on building the elements for the exterior. Continue reading
A year or so back my long time hacker friend Dichro made some lock pick earrings to wear in case of emergencies. Di asked me to give a go at some slim, elegant, sophisticated ones that pass as everyday jewelry. After some poking and testing and experiments, I believe I’ve come up with just that.
[code]An elegant accessory, perfect for quick escapes, late nights, and lost keys. These acid etched stainless steel earrings are lightweight and feature a selection of picks, rakes, and a tension bar. They’re decked out with silver plated rings and ear hooks.[/code] Continue reading
I’ve been really excited to work with Pork Pie Hatters over the last few months. I’ve made hat stands, hat blocks, and some fun laser cut experiments for them and it’s been sincerely fascinating to find ways to blend their classic hand crafting tools and techniques with the kind of digital fabrication that can bring mass production polish to boutique small run items.
As part of defining the look of Pork Pie Hatters products and bringing some cohesion to their packaging, they commissioned me to make a set of huge stamps to brand their cardboard hat boxes. Since these giant roller stamps would be inconvenient to hide away in their stores, I decided to make the whole design fit with the old school aged wood aesthetic of the rest of their equipment. Continue reading
As part of a series of projects for Pork Pie Hatters, I’ve been reviving some old hat making equipment through a combination of laser cutting, CNC milling, and some older tried and true fabrication techniques. My favorite of these projects has been a series of hat blocks designed in SolidWorks and milled in ash.
The goal has been to recreate a number of classic hat styles for a complete production run of custom hats. The hats themselves are being fabricated at the Pork Pie Hatters Williamsbug shop. The major challenge of this project has been to recreate a complete series of hat blocks from a series of reference forms and drawings, keeping in mind the key elements crucial to each particular hat style. It would be simple to make a series of hat blocks fit for a complete set of head sizes by taking a single design and scaling it up or down. But, the crucial gesture of each design would be lost. The features like pinches in the front, the curve of the ridge along the crest of the hat, the indent at the top of a pork pie, all shift and scale independently to work holistically on different sized heads. Continue reading
Over the past few months I’ve been working with Melissa Dowell to make these lovely Narwhal Skewers and now (after a good deal of prototyping, experimentation, poking, and prodding) they’re finally out. The process that went into these is actually kind of fascinating first because of how difficult it was to hone in on the right way to design these in CAD and secondly because of how many different directions we explored before finally landing on the final design.
The whole project started with some sketches from Melissa. From there we chatted about ideas, industrial design considerations, and manufacturing constraints. I felt that it would be reasonable to fasten a twisted rod into a cast metal handle and we could core out the handle to provide both the fastenings for the rod and minimize weight and material.
Melissa sculpted an oversize polymer clay narwhal that we finessed and modified until it had the desired gesture and proportions. From there, we took it to Numidas Prasarn to get the thing scanned and digitized. Continue reading
We’ve seen the story about the kid getting punished for eating a Pop-Tart into the shape of a gun in school. Most likely you’ve seen some meta-journalism about the hype cycle on this, what the constant terror about guns means for the state of humanity, and exactly how much navel gazing is appropriate based on one inconsequential piece of news. Chances are you’ve also seen some truly awful leader images for those stories as well. Numi and I set out to change that.
We’ve made a selection of creative commons high resolution images of high fidelity pop tart guns for you to use to your heart’s content. Download them. Use them. Remix them into a food gun collage bonanza. The sky’s the limit.
This will be an update on the things I’ve learned molding quadrupeds over the last couple of months and some previews of the new robots I’ll be experimenting with in the next few weeks. To start, I’ve had the chance to run a gaggle of design experiments ranging from small changes to the particular silicone I’ve been casting, to more radical changes to how the whole plionics manufacturing process comes together.
I’ve discovered that molding complex channels of tubing can be extremely difficult, and the CAD equally infuriating. I’m discovering some automatic routing tools in SolidWorks that could streamline the process, but there might be another solution that sidesteps that whole mess entirely. It’s possible to cast around silicone tubing that’s already connecting up all the interior geometry. So, what I’d have to do to get the design working is build the cores with little fastenings for plugging in tubing and make sure all the tubes have enough clearance to get past one another. I’m anticipating the world of reality doesn’t let me off the hook that easily, but it’s a start. Continue reading