Final Design

Figure 1: SolidWorks Model of Final Design

Project Components

    The final design incorporates an L-beam as the main framework of the structure in order to retain the original design of the Statue of Liberty. The L-beams are made out of Stinger Bored which is a lightweight, rigid material made out of 100% recycled polypropylene satisfying the gray stipulation of the use of a green material. Additionally, Stinger Bored is water proof because it is a thermal plastic since the structure will be displayed outside. In order to create the L-beam, corner brackets are utilized to hold the flat slabs in place. The corner brackets are fastened with a cap screw, tee-nut and washer set. 

Figure 2: L-Beam Shape

Figure 3: Stinger Board

    Each L-beam is cut into at least three separate pieces to facilitate transportation and these pieces will be fastened together, again, using a tee-nut, cap screw, and washer set. There is also two connection pieces that will not only elongate the lengths of the beam but to also reinforce the cut. 

Figure 4: Piece-to-piece Connection

Figure 5: L-Beam with Connection Pieces (CAD)

    The installment of a metal pocket around the four legs of the structure is also utilized for extra support around the base of the Pavilion. This also facilitates deployment because the metal pockets will act as a guide for the vertical legs to slide into place. Additionally, the cross sections are deployed using a pivot style method around a housed ball bearing.

Figure 6: Metal Pocket

Figure 7: Metal Pocket (CAD)

Figure 8: Housed ball bearing

    Lastly, a projector screen is to be hung from the overhang seen to the left in Figure 1. Along with a projector placed outside the structure, images will be back projected on the the trapezoidal-like shape created from the overhang. 

Figure 9: 6061-T6 Aluminum Overhang

Figure 10: 6061-T6 Aluminum Corner of Overhang

Figure 11: Projector Screen

Project Deployment

Below the steps involved in construction are outlined:

• 1. The team assembles the base perimeter, vertical legs, and cross-bar sections on the ground.

• 1. Metal pockets are placed in each corner of the base perimeter.

• 1. Vertical legs are lifted and placed in their corresponding pockets and fastened with ¾” bolt.

• 1. Each corner of the roof is lifted and placed onto the top of the vertical legs and secured.

• 1. The intermediate pieces are placed between each corner of the roof and fastened together.

• 1. The cross-bars are placed across each face of the cube in both directions.

• 1. Attache metal overhang to side of structure.