Irregular Tulip Press Fit

Utilizing laser cutting technology and Fusion software, I created a 3D irregular tulip. Irregular because the petal pattern on each face is unique. I chose this design because of my love for floral designs. Initially I thought I could use this as some sort of decor in the apartment, perhaps make multiple small tulips and create a garland. I may still in the future move forward with this idea.

Supplies:

1. Fusion 360 Autodesk Software
2. Laser cutting tool from MAT 111PF library, kerf 0.25mm
3. 1/8" plywood
4. paper
5. pencil/pen
6. Laser cutter

Beginning with idea formulation, I sketched some potential structures for my final press fit. After deciding upon the tulip, I elaborated on configurations for the model. Similar to a paper form, I broke the piece down into its basic shapes then sketched estimated proportions for each component. I also marked where the prospective pieces would fit together to gain a better idea of the base requirements of my design to implement in Fusion.

Moving into fusion, I created digital sketch making digital components for each section of the piece. Initially, I struggled with creating multiple sketches for each component. After figuring this out, I faced challenges trying to mirror the petal patterns on each face of the model in different sketches. So following the flow of the art, I decided to intentionally keep each face irregular adding character to the piece. I enjoyed using the "point" function to help set-up my splice line through the "fit-to-point" function -- this function enabled a more organic design to take shape. After fitting these together in the final set-up and manufacturing.

Here, I was able to move my components to ensure they would properly fit together in the final product. Some adjustments had to be made for the half-lap joint of the blossom as there was a gap between the indents of both pieces. After making the appropriate adjustments, I readied it for export. I created a 6"x8" rectangle to lay the pieces on to make sure that they were properly sized. It took a few attempts to get the pieces to lay flat, but after arranging them as compactly as possible, I exported the arrangement.

After exporting the file to the laser-cutter, I cut out the pieces for my product. I accidentally misjudged the scaling and cut the pieces too large. I also forgot to adjust the kerf which prevented the oversized pieces from fitting together tightly. So I made quick edits the kerf setting and utilized the camera feature of the laser cutter when sizing my pieces for cutting, then cut a second attempt. This one worked perfectly with pieces being appropriately sized and tight fit between the half-lap joints with no gaps. Other than pushing the pieces together, there was no other refinements necessary for the intended final product. I would have liked to include more definitions in the petals and maybe even more face panels, however, I was happy with the final product as a pocket-sized decor item and its overall appearance.

**my laser cutting video did not load so I've uploaded a screenshot!

Overall, I really enjoyed this process and looked for to making more 3D designs. I found the component generation process really satisfying, especially when ensuring fit between the half-lap joints, then finally seeing it all come together. In the future, I may cut a couple more varying sizes of my design to create the initial imagines bouquet. Additionally, I would like to use alcohol-markers in the future to color the petals, stem, and leaf. Thank you!

I found the reading to be a refreshing take on the design process – almost in the vein of Bob Ross’ idea of “happy accidents” where the design process is guided by the materials and their interactions. Though I ended up using a top-down approach for my design, I kept the notion of letting the materials guide the process in mind. My thought was to design a tulip-like flower with a stem and this process unfolded within the capacities and framework of fusion. I let the spline function take a unique shape for each face of the blossom – resulting in the Irregular Tulip. I also let the design take form as I created each piece without a super certain idea in mind, such as where the leaves should be or how many petals should be on each blossom face. I look forward to seeing more implementation of bottom-up installation designs such as that produced for the 2016 summer paralympics!