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Test Modelling
Test Modelling
Good designers will build many test models to help develop their design from their initial idea into a better solution.
Making a model gives you something to hold so that you have a better idea about the size and scale of your design as well as understanding how well the features of your idea work.
Models allow you to understand if you need to make any changes or notice what doesn't work before making the real product.
Test models always use easy-to-work-with materials that are cheap, easy to cut, easy to shape, easy to model and easy to purchase.
Examples of test models made by real design teams
Examples of test models made by real design teams
Globally minded
During this lesson you will learn skills that are commonly used in industryMany different types of materials can be used top create a Test Model, such as: card, cardboard, styrofoam, clay, plastic or wood.
How to make your own Test Model with MDF and blue foam
How to make your own Test Model with MDF and blue foam
Both MDF and blue foam are great materials to work with to make a quick and easy test model.
Why is MDF and blue foam the right materials for this Test Model?
Easy to cut and shape with hand tools
Sanding is quick and easy and leaves nice smooth edges if done correctly
Light weight
All tools can be used to help shape and design your model - even cutting knives, pencils and needle files
Can be painted or glued
Predictable material because it is man made- there is no grain, no air bubbles, no cracks or splits and the density is consistent throughout the material.
The shape/model can easily be adapted at any stage
Cheap
Step 1: Draw your design onto the MDF and foam. Think about your design shape and where your fingers will hold the device.
Step 1: Draw your design onto the MDF and foam. Think about your design shape and where your fingers will hold the device.
Step 2: Cut out the rough shape by using hand tools, cutting knives or the scroll saw
Step 2: Cut out the rough shape by using hand tools, cutting knives or the scroll saw
Step 3: Sanding and shaping your Test model.
Step 3: Sanding and shaping your Test model.
Choose the correct shaped file for the groove you want to cut. Use the table vice.
Use both rough and smooth grades of sandpaper to get a nice finish.
The blue foam is easy to snag, tear and rip so you should sand, cut and shape with care.
3 different example models. Each one has a different design or different features.
This photo shows the backside of the Test Models and shows the finger/hand grips.
A close up photo of a finger grip on the edge of one of the Test Models.
The images below describe the step by step progress of making a blue foam only model
Choose the right size of foam
Check the thickness is correct or use multiple layers
Place the Micro:Bit on the top and draw around the template
Use a flexible curve ruler to mark out your design. Use a pencil
Use a coping saw to cut out the main shape of your design
Follow the pencil lines as a guide
Your rough shape should have been cut out and ready to sand
If you have holes, use a drill
The drill will create holes for you to insert the saw blade
Insert the saw blade through the hole and begin cutting
Cut out the internal hole and follow the guidelines
Check that you have followed the design accurately
If you have rounded edges, use the coping saw to cut away larger chunks or material
Cutting large chunks of material is easier than sanding by hand
You may use a file or sandpaper to finish the edges
Add any features to the design like grips carefully. The foam can tear and rip easily
Internal cutting or shaping can also make use of the Hot Wire cutter
Internal cutting or shaping can also make use of the Hot Wire cutter
Other cutting options
Other cutting options
A craft knife may also be used to cut out thinner layers.
Thinner layers can then be built up and stuck together to get the correct thickness.
Working in thin layers can give you more control of the shape, design and how you cut.
Always use a cutting mat, goggles and cut away from your other hand (in case you slip and slice a finger!!).
The hot wire cutter can easily cut through foam if the heat settings it correct.
Set the temperature between 7.00 - 8.00
Use 2 hands to glide the foam through the hot wire. Keep it flat on the top so it's stable.
Cut too slowly and your foam will melt, push too fast and the wire will snap. test on a scrap piece first.
Take time to mark out and cut out your micro:Bit slop so that you have a tight fit. there should not be any gaps.
You can sand the edges for a nicer finish.
Student examples below show the range of possible designs and how the foam can be shaped
Student examples below show the range of possible designs and how the foam can be shaped
Student example #1
Smooth edges. A raft knife, files and sandpaper were used to achieve these results. The Micro:Bit fits well but does show some gaps and spaces around the edges of the slot that shouldn't be there.
This is in a good position for final development where minor changes can be incorporated.
Student example #2
External edges are smooth and have been finished nicely but the slot to house the Micro:Bit has many gaps showing the pencil guidelines may not have been followed.
Student example #3
Cut and sanding shows good results. the internal Micro:Bit slot shows a tight fit indiciating the guidelines have been followed carefully when cutting.
Student example #4
Student example #5
Student example #6
Task
Task
Manufacture your test model.
Take photos of every step of the process.
Present step by step the process of you manufacturing your model on your site.
Write an Evaluation of your model on sites.
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