RMS - Emerging City Views - OMAX 5-Axis Waterjet Double Layered Tilt Cut With Lightbox

This tutorial and design exploration is for exploring and learning the process that it took to develop the "Emerging Cities" piece for the Autodesk AiR 2016 Show. This instructable is based on a prototype designed for the Resilient Modular Systems, PBC Modular Brick Unit. Resilient Modular Systems is a Public Benefits Corp, and leader in innovative sustainable modular components for the building industry in emerging markets.

Each piece has the 5-Axis water jet metal aluminium and a white piece of acrylic with the names of the cities etched onto them. They peer into singular moments within each city, and offer viewers to take a glimpse into the atmosphere and cultural lives of each of the three countries, which were studied and researched for the Resilient Modular Systems project. The cultural values and the economic discourse is an interesting perspective into the views of each of the individual cities. With "Emerging Views", the concept is to allow viewers to hopefully take this into the perspective when accessing the piece.

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Designed by - Wendy W Fok | Founder
Resilient Modular Systems, PBC

Step 1: OMAX 5-Axis Waterjet - Double Layered Tilt

The most exciting part of using the OMAX 5-Axis Waterjet is to ensure that the machine works with all the variables that are playing against the shape, and geometry. The dance with the machine, and making sure that OMAX Intelli-CAM works with the Layout and through the OMAX Make, are the three steps that are suggested to prepare the files before machining the part.

Step 2: Machining Parts

Over seven iterative studies were made, the variable double layered tilt worked with most of the experiments, except for one, which intersected two angled tilts. The best angles to cut on the 5-Axis is no angle larger than 60 degrees, however, the 45 degrees cut works well if it were an exterior cut.

Step 3: Iterative Studies

All of the models were modelled in a 3D CAD modelling software. The shapes could be modelled in Autodesk Fusion, or in the case of these shapes, they were modelled in Rhinoceros 3D. These shapes were then tested for accuracy for prototyping, but also made to offer a speculation of various oculus depths, and ranges.

The polishing of the interior frames were the most challenging, and therefore, each interior window takes around 15 - 30 minutes of polishing before achieving a semi-reflective shine. There is still a lot of exploration necessary to figure out the best next steps for establishing a more reflective shine within the frames, without resorting to the sandblaster. Currently, they are all hand-polished with sand-paper.

Step 4: Transparency Install

After the pieces are carefully polished and sand-papered. Transparency film were printed on with the various imagery of the emerging countries that this project is looking to explore. The piece itself is to also reflect on the various "views of the cities" that bring an interesting discussion on the emerging qualities of countries with economies of scale that could be further explored.

Within this piece, the following Countries were explored:

Colombia
Dominican Republic
Cuba

Step 5: Lightbox Assembly

For the design of the interchangeable light-box system, we bought a LED lightbox system that would be used to install within kitchens and recessed lighting. This ensured the white 6000K white light that was made to offer through the LED. Most LED kits do not come with the wall plugs, therefore, it would be suggested to purchase this and add a breaker between the LED kit to fit with the wall plug. Basic electronics is required before making this fit out.

The external box itself was designed in Adobe Illustrator, and cut into the shape for the effect of a polished look, with the words, "Emerging Views" (title of the piece) on the front to ensure that viewers were able to interchange the ocular window pieces that view into the various cities.

Step 6: Finishing

Each piece has the 5-Axis water jet metal aluminium and a white piece of acrylic with the names of the cities etched onto them. They peer into singular moments within each city, and offer viewers to take a glimpse into the atmosphere and cultural lives of each of the three countries, which were studied and researched for the Resilient Modular Systems project. The cultural values and the economic discourse is an interesting perspective into the views of each of the individual cities. With "Emerging Views", the concept is to allow viewers to hopefully take this into the perspective when accessing the piece.