MATERIAL SYSTEMS

I started my design journey by exploring the concept of interlocking and span, with the goal of creating a balance between strength and visual appeal. I drew inspiration from the intricate interlocking mechanisms found in Japanese design and created a series of small, modular units. Through experimentation and refinement, I combined these units to form a cohesive structure, ultimately achieving a design that seamlessly blends form and function.

The basic unit formed the basis for two geometric ideations, which I evaluated for their aesthetic appeal and ability to span the required distance. After careful analysis, I selected these two most promising options, recognizing their potential to balance form and function.

At a critical point in the design process, I drew inspiration from the turtle shell's unique geometry, which combines triangular and hexagonal patterns to achieve exceptional strength and stability. This insight informed my decision to select the second ideation, featuring a triangular unit and hexagonal geometry, which proved to be more stable and better suited to span the required length. The resulting design met functional requirements and exhibited a unique, visually appealing aesthetic, making it an ideal solution for the project.

The subsequent step involved selecting a suitable material for the design. Seeking a medium that offered a balance between durability and flexibility, I explored alternatives to traditional wood and cardboard. My research led me to Medium-Density Fibreboard (MDF), a material that presented an ideal compromise between hardness and pliability. I opted for MDF and proceeded to scale up the interlocking design, creating a larger version that maintained the integrity of the original concept.

Following the assembly of the interlocking system, I observed a noticeable sagging effect between the cells, which compromised the structural integrity of the design. In consultation with my professors, it was recommended that I investigate the use of a lighter material to address this issue. Despite achieving a design that mimicked the turtle shell, it became clear that the structure lacked the necessary strength to support its own weight. I subsequently proceeded to implement the professors' suggestion, seeking a material that would strike a balance between weight and structural rigidity.

Following the recommendation to explore alternative materials, I selected ice cream sticks as the ideal candidate for my design. The primary advantage of using ice cream sticks was the consistency in their dimensions, which provided a constant height and length that facilitated the creation of a precise and accurate design. The uniformity of the ice cream sticks enabled me to develop a modular system, where each component could be easily replicated and assembled to form a larger structure. This consistency in material dimensions was crucial in ensuring that the interlocking mechanism functioned as intended, and that the overall design maintained its structural integrity. By utilizing ice cream sticks, I was able to achieve a high degree of precision and accuracy in my design, which was essential for creating a stable and functional structure.

Although I had switched to a lighter material and shorter length, the sagging issue at the interlocks between the cells remained unresolved. To identify the underlying cause, I re-examined my initial unit and discovered that the uneven stems of the ice cream sticks were the primary issues. These uneven stems, which were retained in the interlock, disrupted the weight distribution throughout the system, leading to the sagging effect. By recognizing and addressing this issue, I was able to redesign the unit and create a new version that eliminated the sagging problem and achieved a more balanced structural integrity.

With the redesigned unit in place, I proceeded to create the same geometry with minor modifications, resulting in two ideations.

After evaluating both options, I chose Ideation 2 for its optimal balance of strength, structural integrity, and material efficiency. This design avoided overdesigning the cell, while also minimizing material usage by reducing the number of ice cream sticks required, making it a more sustainable and efficient solution.

The culmination of my design process is the final structure, pictured above, which was brought to life using the refined Ideation 2 design. To achieve the distinctive curved shape, reminiscent of a turtle shell, I employed a modular approach, combining three identical systems, each consisting of the optimized ice cream stick arrangement.