LED lit 2' square steel vertical wall on wheels; walking requires a long sturdy extension cord for full effect. Lighting support provided by my friend John "Parts" Taylor of LumiGeek. CAD file support provided by my friend Aaron Porterfield.
Step 1: Design
I embarked on an exploration of what a living wall could be... I settled on 2' square vertical wall with a center design influenced by sacred geometry, specifically the "Flower of Life".
Step 2: Cardboard prototype
I used the Epilog 120 Watt Laser to cut cardboard into a scaled prototype to reality check aesthetics.
Step 3: Wood prototype
Feels pretty good, let's move on to metal...
Step 4: Steel Frame
Cut 2" Steel Square Tube into sections to create a 24" x 24" Vertical Frame and 10" x 24" Horizontal Base. Reality checked the Golden Gate Bridge art piece on top of the wall - GGB is a bit much, as it feels like it overpowers the Living Wall's presence...
Step 5: Waterjet cutting the "Flower of Life" into 1/16" thick Steel sheet
I cut the design using the Omax waterjet. The Cut file was the most challenging given the 64 individual cutouts, mostly straightforward removing pieces as the cut progressed. Files attached - enjoy :)
Step 6: Sandblasting and Welding, and more sandblasting
This step went smoothly...
Step 7: Painting the Wall
We have come full circle in getting the finished frame and inset design back to metallic color; I used Krylon Nickel Shimmer and painted it in the spray booth (very important considerations involved given the Pier 9 location on top of the San Francisco Bay).
Step 8: Diffuser tubing to block direct viewing of LED lighting
I used High-Pressure/Vacuum Polyethylene Tubing (0.814" ID, 1" OD, 3/32" Wall Thickness, White) to make strips that fit between the frame and the interior design to block direct viewing of the RGB LED strip that I will be running inside the frame. I used a Pneumatic Shear to cut the tubing in half longways, then a Dremel with the 1" cutter attachment to notch the tube ends to fit into the frame. Video is of me using the pneumatic shear; http://youtu.be/1hWyR1Qb8sI