By Shengli Wen and Evan Bird

From start to finish, this project was an exploration of the boundaries of the 2D plane and how assembly and pattern-making could make something greater.

The first step was exploring possible shapes from which to make a structure from.

Staying within fixed guidelines for the size of each shape, those with points such as stars and triangles proved to be interesting, so we formed paper prototypes to test possibilities.

Subsequently, after assessing material restrictions, we sketched an initial CAD prototype of a 6-pointed star. We decided to plan to attach them using screws positioned in cuts in the wood to allow for consistent variability. 

Using a laser cutter to print these designs into 1.5mm plywood, we were able to test the viability of this design using a small-batch test run.

Because of our goal to make a 3D structure from these materials, we wanted to find techniques to bend the wood. Then, all the pieces together would be able to form something larger. With this prototype, we found the points on each star were too prone to breaking, so we reimagined the same form with stronger edges.

From this design we were able to do a large scale print and start further production.

Assembly comprised of soaking some of the stars and meticulous attachment of points together. From many became one, and differently shaped sections began to form, which then could finally be attached to form the final pangaea -like structure.

To complete the installation, we imagined the structure hanging from above in order to fully show its dimension. We also tested including an aspect of natural imagery finding its way in and out of the structure. The product proved to be successful at forming something completely different than the original design through mass production.