Fab-in-a-Box Automata

Several examples should be provided to show different types of movement.

Many great examples are available online, but seeing the mechanisms in person can be especially helpful to understand how they fit together.

One example of rotational-to-reciprocal movement (turn the crank to make the topper rise and fall) -plus- one example of horizontal rotational to vertical rotational movement (turn the crank to make the topper spin in a circle) should be sufficient in most contexts.

Offer examples of different shapes and combinations of cams, and the types of motion they create.

Welcome:

Welcome class and open discussion of what we are doing today.

Show the example of an Automata and discuss how cams and gears work.

Explain the Engineering Design Process.

Explain CAD (Computer Aided Design) Software.

Key terms:

1. Automaton: A mechanical device designed to move in a predetermined way, often powered by gears, cams, or levers.

2.Gears: Rotating components that transfer motion and force within an automaton.

3.Cams: Irregularly shaped discs that convert rotational motion into linear motion.

4.Linkages: Mechanical connections that control movement between different parts.

5.Kinetics: The study of motion and forces affecting mechanical systems.

6.Tolerance: The acceptable variation in dimensions for fabrication accuracy.

Context:

From the Greek word automaton, which means “self-moving,” automata are kinetic sculptures that exhibit movement through mechanical means. They lie at the intersection of art and engineering, requiring both creative vision and a working knowledge of mechanical principles to construct. 

Historically, automata were akin to magic, moving in highly complex ways driven by (sometimes hidden!) hand-cranked gear systems. Today, technology enables remote control through motor-powered systems.

Activity Steps:

Note: we suggest fabricating driveshafts that are flat on one side rather than cylindrical (e.g. 3D printed from provided file instead of using skewers or dowels). Coupled with cams with the same holes, this prevents cams from spinning freely on a round shaft, and eliminates the need for adhesives to keep them in place. 

Experiment

Assemble your box frame. Make sure the holes for your driveshaft are aligned. Use glue as needed to hold the panels together.

Press-fit your follower onto the follower rod. (Use glue as needed to keep it in place). Flip your frame upside-down and thread the follower rod through the hole in the top panel. 

Thread your driveshaft halfway through the hole in one side of your frame. Add any cams in the appropriate orientation to achieve your desired motion. Then thread the driveshaft through the hole in the other side of the frame. Add a crank to one side and a press-fit stopper (or blob of clay) to the other, to keep it from popping out.

Flip your frame back over, right-side-up. Place the follower atop the appropriate cams, adjusting the cams’ placement on the driveshaft as necessary for alignment. 

Give your crank a spin! Does your follower shaft move as expected? (Adding a small post-it note “flag” to the top of the shaft can help make spins, twists, and turns more easily visible). Experiment with different cam shapes, combinations, and positions to achieve different types of motion. Document your experiments, noting observations and findings related to gear ratios, cam profiles, and follower placements.

Ideate

Now that you’ve seen what’s possible, brainstorm the movement you want to create. Consider characters, actions, and scenes that could come to life through movement to help you tell a story.

Sketch your scene. Diagram its movements, and label the components (frame, crank, drive shaft, cams, followers) and mechanisms needed to achieve those movements (shape of cams, gears, etc.).

Consider how you can apply your findings to your automata design to achieve your desired movement and storytelling.

Prototype

Use cardboard cutouts and sketches to rough out your scene. Consider foreground, middle-ground, and background. How can you make a scene with tow objects spinning in front of a background? Take this opportunity to figure out sizing for your objects, and to determine which fabrication method may work best for each.

Design

Create CAD or vector designs for the elements that will bring your scene to life. Consider how they will attach to the top of your frame, to your followers, and (if relevant) to each other.

Note that you may choose to re-fabricate elements of your box frame depending on the design of your topper. For example, if you would prefer to avoid adhesives or want to be able to swap different elements of your scene back and forth, you might laser cut a new top panel to enable tab-in-slot assembly.

Intro

Design and fabricate your own custom automata. 

Activity Steps

Click OPEN on the xDesign landing page

Click the “Minimize” icon in the upper right-hand corner of the Search results page

— the results will be repositioned to the right-hand side of your screen so you can see things alongside your xDesign session

Type “Lesson9” in the Search field, [2] press Enter on the keyboard, then [3] click on the blue header bar (to dismiss the Search History panel)

— the Search results will update to show you the automata template

Drag the Automata template into your xDesign session and then [2] click “X” in the upper right-hand corner of the Search results panel

Click SAVE AS… in the dialog that appears

Type a new name for the component (perhaps add your initials) and then [2] click SAVE

Click the “Solve” button on the Action Bar to update the assembly’s mates

This will clear the warning symbol on the Top Level and Mates nodes in the Design Manager

Click and drag any part of the orange handle and turn it to see how the bevel gears inside move

Click “Save” on the Action Bar to save your custom die

Prepare files

Save your design files in the appropriate format for your fabrication method.

Load them into the software appropriate for your machines and prepare them as needed.

3D printer: STL files, sliced in Bambu Labs

Laser cutter: SVG files with power settings calibrated in XCS

Vinyl cutter: SVG files with power settings calibrated in Brother Canvas Workspace.

3D Printer Safety Note: Never leave a 3D printer unattended, especially during extended prints. Ensure the 3D printing area is well-ventilated to avoid fumes and particles. Open windows or use a fan to circulate air. Avoid touching the hot extruder, nozzle, or heated bed. These parts can cause burns. Be aware of moving belts, gears, and other mechanical parts that can pinch or injure hands. 

(Students should be encouraged to run the machine with instructor supervision!)

3D Printing

Import Your 3D Model:

Open Bambu Studio and start a new project.

Import your STL or 3MF file by dragging it into the workspace or using the File > Import option.

Position & Adjust the Model:

Use the Move, Rotate, and Scale tools to adjust the model’s placement on the build plate.

Ensure the model is properly oriented for optimal printing.

Select Printer & Filament Settings:

Choose Bambu PS1 as your printer from the dropdown menu.

Select the filament type you’ll be using (PLA, PETG, ABS, etc.).

Adjust temperature settings based on filament recommendations.

Configure Print Settings:

Set layer height, infill density, and wall thickness based on your desired print quality.

Enable supports if your model has overhangs.

Adjust bed adhesion settings (skirt, brim, or raft) if needed.

Slice the Model:

Click the Slice button to generate the toolpath for printing.

Review the preview tab to check for errors, estimated print time, and material usage.

Send to Printer:

If connected via Wi-Fi, send the sliced file directly to the Bambu PS1.

Alternatively, export the G-code to an SD card and insert it into the printer.

Laser Cutter Safety Note: Never leave the laser unattended! Laser cutters use high-powered beams that can ignite flammable materials like wood, paper, and plastic, even if the metal being cut doesn’t ignite. Slag from cutting metal can also start fires if flammable materials are nearby. If the laser cutter is being supervised, a CO2 fire extinguisher can usually put out a fire quickly.

(Students should be encouraged to run the machine with instructor supervision!)

Laser Cutting

Connect laser cutter:

Turn the laser cutter on and connect it to your computer via USB.

Open xTool’s XCS software (download here).

Select “connect device” in the upper righthand corner of XCS.

Choose your laser cutter from the pop-up menu.

Import design file:

Click the file folder icon in the upper lefthand corner. From the dropdown menu, select “import image.” Choose your file.

Select the circular handle to rotate your design as needed to fit onto your stock. 

Note: do not resize within XCS! Remember: your design is parametric, and the holes are perfectly calibrated for the width of your design. If you resize outside of your CAD environment, these will also change.

Configure cut settings:

Select “user-defined material” from the dropdown materials list.

Combine all elements (lines) you want to cut on a single layer. 

To add or switch layers, click “move to.”

Select “cut” under the “processing type” menu.

Check settings

For 1/16” balsa wood, we suggest the following (power/speed/pass):

Score: 40/150/1

Engrave (raster): 30/200/1

Cut: 100/15/1

Note: the machine will automatically score and engrave before it cuts, and cut inside elements before outside elements. 

Prepare laser cutter:

Open the laser cutter lid and place stock (balsa) onto the honeycomb. 

Manually drag the laser head over the center of the stock.

Close the lid.

Click “auto focus” and wait for the machine to focus. 

Open the lid. Manually drag the laser head to the top left corner of the desired cutting area.

To check framing, click “framing” in XCS and then press the button on the machine. The laser head will frame the area to be cut. If it does not fit on the stock or overlaps a previous cut, adjust the starting position as needed.

Run the job:

Click “process” in XCS, followed by the button on the machine.

Remove pieces:

Check to make sure all pieces are cut through, and rerun (adjusting settings as necessary) if not. 

Remove workpieces and scrap stock from the machine bed.

Close the lid.

Vinyl Cutter Safety Note: Operation of this device requires use of sharp blades and caution should be taken to make sure that fingers do not get caught in moving gears during operation.

(Students should be encouraged to run the machine with instructor supervision!)

Vinyl Cutting

Prepare the machine: 

To turn the machine on, long-press the power button on its right side for 2-3 seconds.

Open the machine’s hood.

On the tool carriage, pull the locking mechanism completely out.

Place the autoblade into the tool slot, and make sure it is fully inserted.

Push the locking mechanism back into place.

Prepare the cardstock:

Use a light hold cutting mat (or one where most of its “sticky” has worn off.”

Position your cardstock on the paper.

Load prepared cutting mat into the machine.

Configure cut settings:

In the silhouette software, turn on “line segment overcut.”

Run job:

Click “send.”

Remove your pieces:

Don’t peel the paper off the cutting mat! Instead, turn the whole thing upside down and peel the cutting mat off the paper instead.

Assemble

With your pieces fabricated, it’s time to assemble your automata! 

Make sure your followers are properly aligned with your cams or gears.

Give your assembled piece a spin!

Extensions & Discussion Questions:

Does your automata behave as you expected?

Are you able to achieve your desired motion?

How can you combine mechanisms to achieve multiple movements, either in unison or in sequence?

How you can apply your findings to your automata design to achieve your desired movement and storytelling?

If you were to teach this lesson to your peers, what would you do differently?

Optional Tie-ins:

Art & History: Explore historical automata, such as 18th-century mechanical dolls or early clockwork devices, to show the evolution of kinetic design.

Physics & Engineering: Discuss concepts like motion, forces, and mechanics that influence automata function, making connections to real-world applications.

Mathematics & Geometry: Analyze gear ratios, cam shapes, and linkage designs to integrate mathematical principles into the fabrication process.

Coding & Robotics: Compare traditional mechanical automata with modern robotic systems that incorporate sensors and programming for enhanced interactivity.

Storytelling & Animation: Have students design automata that convey a narrative, mimicking animation techniques used in stop-motion filmmaking.

Environmental Science: Highlight sustainable materials and efficient fabrication methods to explore eco-friendly design solutions.

Career Connections:

Industrial Designer: Creates functional and aesthetically pleasing products, often incorporating kinetic movement and mechanisms.

Automation Engineer: Works on automated systems for manufacturing and robotics, applying principles used in automata.

Art and Installation Designer: Creates kinetic sculptures and interactive exhibits using mechanical movement.

Biomedical Engineer: Designs prosthetics and assistive devices using similar fabrication techniques.

Theme Park or Special Effects Designer: Develops animatronics and moving displays using automation principles.