The design build team at the US Space & Rocket Center in Huntsville, Alabama.
We went through many concepts during the idealization process of design. The challenge was to create a vehicle that was lightweight and collapsible. For seating, we settled on a back to back design for optimal weight distribution and improved handling. We chose a tri-wheel design to minimize weight while maxmizing stability.
I enjoyed working with three other teammates in determining the best seated positions for optimal efficiency and maintaining a sporty design. Lots of models were created using thin strips of plywood to determine the best fit on the body. The final dimensions were translated to a CAD program, then a mold was cut with a CNC on foam. Carbon-fiber was chosen for the seat material for its light-weight and durable qualities.
The fabrication of the frame required many hours of braising, welding, cutting, fitting, etc. Then, the rover was assembled using custom machined parts as well as bicycle components.
Art Basel Miami Process Images
Most of the building was built in parts in a fabrication shop in NYC. The roof and final assembly was done in Miami.
Rhino 3D model
Curved walls internal structure
The construction of the walls were cut on the CNC
Curved walls and roof panels being constructed off-site
Laying down the foundation in the sand
Working late into the night
Roof panel install
Building the stage
Getting ready for the opening
Opening night - Reconstruction of the Universe - Audemars Piguet
Solid NYC crew
Birch Side Chair Process Images
1/8" Scale Model
Visualization of aesthetics and porportions of the design
Full Scale Model
Finalization of a geometry that is comfortable to sit in. Preparation for fabrication.
Creation of a CAD Model
Rhino model used for reference and mold making
Foam mold model for lamination
CNC routing mold model out of foam
Lamination process of layers of baltic birch plywood
Vacum press was used to apply pressure evenly on the foam mold
Steel frame fabrication
Cold rolled steel was bent into the desired shape and welded together.