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 →
I’ve been designing things for Pork Pie Hatters for a year, now. This has included their site, a custom door, some signage, an extra large stamp, a series of hats, and a host of other things. Recently, we’ve been talking about displays, interior decoration, and finding ways to maximize the hats on display while keeping a lid on the clutter. The main problem with selling anything in Manhattan is finding a place to put any stock that isn’t out on the shelves, and the problem with buying anything in Manhattan is sorting it into your microscopic apartment. So, I came up with some flat pack hat stands.
The idea is to send folks home with hats on their heads and a flat pack hat stand, so they don’t have to find room in their lives for a hat box. Traditionally hat boxes come as flat cardboard assemblies that you construct into these 2’x2’x1′ nightmares, or they’re fully assembled oval extrusions whose main aim in life is to take up space. Continue reading →
I made little foldy zoetropes to send folks for the holidays. Now that they’re all sent out and people have had a chance to enjoy them, I figured I could reveal the design without anybody feeling less special. I should release the design and talk about the process behind making them. I should have time for that soon. In the meantime, check out the construction tutorial video after the fold. Continue reading →
I’m a big fan of Princess Jellyfish. It’s stuffed with features and themes near and dear to my heart: gender identity and ambiguity, discovering a world outside your nerd bubble, finding outlets for your passions through building things, how style and aesthetics are a language unto themselves, the clash of cultures between the nerdy and the stylish. It’s lovely stuff.
For Halloween, Numi and I decided to have a Princess Jellyfish themed party. This mostly involved taking an idea we’d been scheming for a long time, a bento box featuring laser cut nori illustrations, and lavishing some love and attention on it. This also meant a day spent snacking on fried things, hunting around for esoteric ingredients all across town, and watching anime on youtube. Good times all in all, especially after being cooped watching Sandy rage outside. Continue reading →
So, after some trial and error, I finally have some lovely TARDIS rings to show off. They’re cast from a high resolution 3d print generated in SolidWorks. One of the beautiful bits about using a CAD program to drive the design is that I can change the proportions of the ring, shank, and TARDIS independently while keeping it within some attractive, reasonable proportions.