This week’s practical, we had been introduced to the different ways and techniques to join the cardboard, in short the cardboard joineries to make a product that we wanted. In this case, corrugated fibreboard was used. Before that, we were also introduced to the fundamentals technique and tools to start building cardboard structures and mechanisms.
First of all, what is Corrugated Cardboard❓❓❓:
Corrugated Cardboard is made from 3 components which are:
Flute on the centre
One outer liner
One inner liner
Figure above shows the illustration of components of cardboard.
One of the factors that define the properties of the corrugated materials is the type of paper used. The most common papers used for the liners are Kraft and Test.
Kraft Paper
Kraft paper is made up of “virgin tree” which made the paper to be the strongest and also easier to print on. Figure below shows the Kraft paper.
Test Paper
Test paper is commonly used as the inner liner. Figure below shows the test paper.
For the flutes, it is commonly made up of :
Semi Chem (SC) which is made up of virgin fibres.
Waste Based (WB) which is made up of 100% recycled fibres.
For the flutes, it is commonly made up of :
Semi Chem (SC) which is made up of virgin fibres.
Waste Based (WB) which is made up of 100% recycled fibres.
Besides that, it is also important to consider the weight of cardboard papers which are standardized in units of gram per square area (GSM). One of the most commonly weights for the cardboard papers is 115/125 GSM.
Different flutes' height or size can achieve different characteristics. There are different types of flutes such as A, B, C, E, F flutes.
E flute:
1.5mm in thickness, providing a very fine tube.
Gives excellent compression strength and crush resistance,
High quality surface for printing
Figure above shows the E flute.
B flute:
Figure above shows the B flute.
C flute:
Between 3.5mm and 4mm in thickness.
Greater compression strength than B Flute
Provides better stacking strength when used for lightweight products
Figure above shows the C flute.
BC flute:
Double wall material of B and C flutes,
Commonly for producing shipping boxes providing a higher level of transit protection.
Figure above shows the BC flute.
EB flute:
Double wall material of E and B Flutes, giving an
Excellent balance between transit protection, strength and print finish.
Figure above shows the EB flute.
Actual experimental work❗❗❗
Firstly, our lecturer had taught us some of the ways to join the cardboard together.
Below are the examples of the cardboard joineries:
1. Tabs
2. Tass
3. Skewer
4. Slots
5. Gusset
6. Score
7. Bend
8. Flange
Picture below shows the summary of the cardboard joineries.
Our task is to produce a visual board by making use of the joineries to join the cardboard together as many as possible. So, our group decided to make use of these joineries to make a house which consisted of these joineries.
Work In Progress… ❗❗❗:
Here are some of the photos taken during our process.
Our final product 👀😂:
Presentation:
The final session is presentation session. Our group decided to pick two of our members to conduct a presentation of our visual board to other groups. We realised that we did not produce at least 8 cardboard joineries in our visual board, but we did the work with our maximum effort and everyone did a pretty good job.
The Pegasus Assignment:
Ambrose:
This is my assembly of the unicorn. We were given a template of the unicorn.
Here were the process of me making the unicorn.
Parts of the unicorn.
Final product of the unicorn.
The type of folds and joints that mostly used were tab and slot. For example, the head of the unicorn. At first, the head could not maintained at its position after being fold. Therefore, I used the tab technique to secure the head of the unicorn so that it could stabilized.
Next, we will need to find a way to allow the wings to return to its starting position. So, I came out with this idea.
Items needed❗❗❗: 1 rubber band.
1. Prepare a rubber band to attach the wings of the unicorn.
2. Tie-up the rubber band and attach to the wings of the unicorn as shown in the photo below.
3. Here is a video shows how I make use of the rubber band to make the wings to fly.
That is it. The process is simple AF.
After that, we will have to sketch the mechanism to automate the wing flapping. So, I came out with the same idea of the music box.
As the handle is rotated clockwise or anticlockwise, the wings will also follow the rhythm of the rotation of the handle and make the wings to flap.
Joshua:
Following practical 3, we were tasked with individually piecing together a precut unicorn pegasus hybrid from cardboard, with the main focus being the understanding of the cardboard joinery techniques used in a practical scenario.
Here's the template we were given with the individual sections already pushed out.
This is the body of the unicorn, all the joinery in this construct were mechanical without the use of adhesives. So the joinery were tabs+slots. The red circles indicate the already joint tab and slot on the body, while the green circles are where later connections will be made at.
These red tab+slot have a bent slot so as to join the parts in two dimensions.
I built the head next. Then inserted the wings tab into the slot.
In the middle of writing I googled what was a unicorn with wings called, that being an alicorn. So here below is my finished alicorn.
The next task was to automate the wing flaps. I saw that by pushing the inside tabs of the wings back and forth one could flap them, and with a piece of rubber band attached to those tabs, pulling it and releasing the tension would also return the wings to their original position in one motion.
A more mechanized and automatic version would this one down below that I've sketched.
1. A winder is attached to the rear of the toy. When the winder is turned it rotates and compresses the spring, when let go it will unwind and rotate the gear.2. This gear is connected to a gear that is perpendicular to its rotation. The first gear rotates around the y axis while (2) rotates about the x axis. This causes the shaft to rotate.
3. The shaft turns a cam that has a rail built on a shaft body. When the shaft rotates it will shift the rail which will cause a component to move back and forth.
4. This reciprocating movement is connected to the wings via an elastic rope, which would be pulled back and forth to flap the wings. This continues until the winder spring loses all elastic potential energy and stops turning the gear, turning the shaft and the cam.
Yongjie:
For our individual assignment, we were given a template for building a unicorn. We used the different joinery techniques to build our unicorn together!!
The head and the body of the unicorn
My final product!! 🦄
Folding, Tabs and slots
For the type of joinery that was present in this product, tabs and slots were used in most of the joints, it held the body and the head together so it won't fall apart!
Next, we needed to help the unicorn to flap its wings!! Of course we need to use our hands to move it but the wings would not return to its starting position and it would be troublesome to move it back and forth.
Hence, to solve this problem, I used a piece of rubber band, secure the two wings together, thread it through the neck (Ouch!), and place the end of the rubber band to the head of the unicorn
Le Mechanism👀
And this is how I move the wings of the unicorn!!
Next we sketch out how can we make our unicorn flap its wing automatically. My idea is to have a gear and motor to aid the flapping of the wings.
As the gear turns, the wire moves back and forth, hence moving the wings with it.
Edmund:
After learning the techniques of making different types of joineries, we had to make our own unicorn from scratch.
Firstly, we need to prepare the parts for the unicorn by dissembling the template provided to us we are left with this.
Secondly, I will start to assemble the body because it is the easiest. I constructed the body using bends, slots, and tabs. I had to use a ruler to help with the bending of the body as seen in the picture.
Thirdly, I assemble the head of the unicorn and it was constructed using bends, slots, and tabs which makes the head more durable.
Fourthly, I assembled the wings, head, and tail on the body of the unicorn making our wonderful unicorn!
However, my unicorn could not fly. Therefore, I created a mechanism for my unicorn to flap it's wings!After brainstorming, I decided to tie a rubber band to another rubber band with two loops and attach the rubber band to the back of the unicorn and by using the bends, slot, and tab to support the rubber band so it doesn't detach from the unicorn. Then, I attach the rubber band with two loops to the wings of the unicorn.
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