Foam Modelling
Foam modelling is used by designers, inventors, architects and design companies around the world to test, develop, refine, test, develop, improve, refine, test etc. design ideas before modelling in 3D CAD or deciding on the final form. Companies such as Apple and Dyson, and most architecture companies use foam models to communicate and test ideas.
What you will do
On a blank rectangular block of blue Styrofoam you need to sketch out your chosen design idea to make a test model, however sketching on blue foam is extremely difficult and so we would recommend creating paper templates first. Ideally, you will create a paper template for each layer of your design so that when your blue foam is cut into 3 layers you will have a template for each layer.
You should find the centre of the block of foam as this will help you add a vertical and horizontal centre line. This will help with sketching your design - see example below.
You will then need to cut your block to the overall 'outline' shape that you have sketched. Your teacher will then cut your block into three (front, middle, back) layers so that you can work on each layer seperately and give you the room for the mosquito coil to be 'housed'. You may wish to use the mosquito coil to sketch around to ensure that you leave enough room for it to be 'housed' in your design.
Once you have completed your model you will need to photograph it from a number of angles and upload and publish these on your website. You will also need to use the photographs within Procreate so ensure that you are able to share your photographs with an iPad.
Step by Step process
Start by marking around the foam block shape. You will need to do this 3 times for the 3 layers that will make up you.
2. Find the centre by using a ruler and sketching diagonal lines from the corners.
Draw out the front view of your design including all details
Cut out your paper template. Ensure your name is on the template.
Your teacher will help you cut your design into 3 layers on the bandsaw.
Now that your shape has been divided into 3 you are now ready to use all 3 templates. The next step will be to cut out the shape for the coil.
Now it is time to use the other templates and add the space for the coil on the middle layer.
This is the middle layer with the cavity shape cut away.
Apply wood glue, Latex or PVA to the foam.
Cocktail sticks cut to shorter lengths can be used to create a better join.
Now it is time to start testing your design and how it is working by putting the layers together with a coil for the first time. Use the mock wood coil for this.
