Crystals

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Project Name Crystals
Contact User:Polyfloyd
Status in progress
Budget 1600
Fabric Length (meter) 0


Like this


A set of about 16 colorful luminous crystal-like obelisks.

The main structure is made out of polycarbonate in a triangular shape, clad with dichroic film on the interior surfaces.

The triangular joints are made by using triangular beams as glue base. Each unit needs about 3.58m for the sides. Beams are sold in as 1m pieces: https://www.kunststofshop.nl/acrylaat-plexiglas/acrylaat-staven/driehoek/acrylaat-transparant-driehoek-staf-1000x8x8x8mm-1000x8x8x8mm/a-5902-20000088

Approx 9m of length needs to be glued per piece. The glue, Acrifix 192 is sold per 100g for about € 26,- which supposedly glues 40m of length.

  • 16*3*2*1.5m = 144m
  • ceil(144m / 40m) = 4
BOM
1 150x100cm polycarbonate panel
1.5m² Dichroic film
9m Acrifix 192 glue
3.58m 8x8x8mm Triangular acrylic beam
1 https://www.hornbach.nl/shop/Plafondfitting-E27-creme/4116393/artikel.html
1 https://www.ikea.com/nl/nl/p/solhetta-led-lamp-e27-806-lumen-globe-opaalwit-30509978/
1 Any power cord
32x32cm triangular wooden board, >=15mm thick
44x44cm multiplex board, 6mm thick
Shopping list
16x 150x100cm polycarbonate panel € 250,-
60x1.38m dichroic film rolls (also used for some other projects) € 368,- +import -> € 400
4x 100g Acrifix 192 glue tube € 104,-
58x 1m Triangular acrylic beam € 346,-
UV lamp € 3,-
16x https://www.hornbach.nl/shop/Plafondfitting-E27-creme/4116393/artikel.html € 63,20
16x https://www.ikea.com/nl/nl/p/solhetta-led-lamp-e27-806-lumen-globe-opaalwit-30509978/ € 27,92


Dependencies

  • Power: About 4 watts per unit

Status

  • 2022-02-25 Mailed Revspace about leftover polycarbonate panels
  • 2022-02-25 Requested samples for dichroic film from Alibaba seller
  • 2022-02-27 Ordered some lighting products from AliExpress to test
  • 2022-03-04 ACK from Revspace, will purchase 16 panels of 150x100cm for € 250
  • 2022-03-16
    • Made a cutting plan suitable for mass production
    • Lasercut a small prototype
    • Ordered 2x 30m of dichroic film, also for other projects
  • 2022-03-18 Started construction of full scale prototype
    • Polycarbonate cutting test, tested glue joints
  • 2022-04-03 Assembly of prototype completed, did some lighting tests
    • The film was applied as a single sheet, rolling the object while the film was being applied. Even with 4 people this resulted in a lot of bubbles.
  • 2022-04-08 Cut the rest of the panels into ~150x32cm at Revspace
  • 2022-04-12 Ordered bulk of glue and triangle rods
  • 2022-04-15
    • Cut panels into exactly 150x32cm
    • Assembled 2nd unit
    • Tested idea for pedestal and light fixture
  • 2022-04-22 Ordered lamp sockets and cables
  • 2022-07-11 Done. Ready for transport

Manufacturing

  1. Cut 150x100 polycarbonate panels in 150x32cm strips

Assembling the polycarbonate panels

  1. Take 2 150x32cm polycarbonate panels
  2. Clean them with dry piece of toilet/kitchen paper to get the rough scraps off
  3. Inspect which long side has the most damage, see if we can get rid of it by cutting smart
  4. On 1 panel, mark the sides at 136cm and 106cm respectively
  5. On the other panel, mark the sides at 136cm and 116cm respectively
  6. For both panels: between the marks you made, apply paper tape where one side aligns with the marks. Make sure to tension the tape so it is completely straight. This is the guide for the bandsaw
  7. Cut the panels along the tape guide you just made. You have to make 2 passes as the band saw can not span the full diagonal distance
  8. Put the panels in the jig, 136cm sides touching each other
  9. Clean the interior-to-be with Alklanet and a microfiber cloth, we can not reach this anymore when all is glued
  10. Take a triangular acrylic rod. Lay it on something that can get dirty. Apply glue to 2 sides
  11. Immediately after applying the glue, flip the rod so the glue is facing down. Lay the rod in the wedge where the panels are touching each other. Move the rod so a ~2cm gap exists at the non-diagonal side of the panels. Be very careful to not get glue on the panels as it is impossible to clean without leaving a stain
  12. Take a 3rd polycarbonate panel. Mark a diagonal line at 106cm and 116cm
  13. DO NOT cut the remnant piece with the bandsaw, we need this to make the top panel later. use a jigsaw to make a rough cut at about 1cm from the marking tape, then do the fine cutting with the band saw
  14. Wait for the glue to dry...
  15. Rotate the previous 2 panels by 120 degrees in the jig and insert the 3rd panel
  16. Glue a triangular rod like before. Because the top side is now closed, you must slide the rod in diagonally and then lower it to a horizontal position when at the right distance
  17. Wait for the glue to dry...
  18. The main shape is now finished
  19. Take the leftover piece from the 106cm,116cm panel and place it on the top of the unit so it covers it, aligning the longest sides. You can use some tape to hold it in place while you are making marks
  20. Mark the edges where the panel touches the sides with tape
  21. Cut the edges with the bandsaw
  22. Clean the top with Alklanet and a microfiber cloth
  23. Put the top in its final position, use some more tape to hold it in place
  24. Apply a bit of glue to relieve the tape. When dry, remove the tape and apply glue all around. Do not use too much or it will drip along the sides which is bad


Applying the dichroic film

  1. The film is a kind of sticker on a big roll. The best way to apply is to cut 3 ~34cm wide strips from the roll. It is important take strips a bit wider than the object surface because it allows for small errors in cutting and the orientation of the film when applying.
  2. Place the object in a jig so the surface you are applying the film to is facing upwards. # Apply the sticker starting in a corner, diagonally working towards the other ends. Use a bank or ID card to press the film down.
  3. Carefully cut any excess film away with a knife. The knife needs to be very, very sharp because you otherwise risk pulling the film from the object, undoing your work.
  4. Use another 34cm wide strip of film for the top panel. The film is much wider than the top, so hang onto the leftover piece, you can use that for the top of the next one.
  5. Bubbles? No problem, take a sharp knife and poke a small hole for the air to escape. Use a bank card or maybe your fingers to push the air towards the little hole you made.

Howto: Prepare

  • TODO: Is there a part in the preparation process that can be performed in parallel by a group of volunteers?
  • TODO: Do volunteers require a specific set of skills?
  • TODO: How many volunteers over how many hours are required?
  • TODO: Is the preparation bound to a specific location?
  • TODO: How much space is required to store the project before it is moved to the event site?

TODO: Describe the manufacturing process in the highest level of detail.

Howto: Buildup

The pieces are stored ready for transport at Bitlair.

  • 1x volunteer to assemble pedestals (need screwing machine)
  • 2x volunteers to deploy in 4 runs with a bolderkar
  • TODO: Should Team Logistics be involved in moving the project to the event site?
  • TODO: How many volunteers are required?
  • TODO: How much time is required?
  • TODO: Provide instructions on how to set up the installation on the event site.

Howto: Teardown

  • TODO: Throw/give away?
  • TODO: How many volunteers are required?
  • TODO: How much time is required?
  • TODO: How much waste in cubic meters is produced?