Fab-in-a-Box Automata: Deep Dive

Prepare a range of inspiring automata examples that showcase both mechanical creativity and storytelling. These might include whimsical characters, narrative scenes, or abstract motion sculptures. At least one example should be actively cutting or assembling as learners arrive to set the tone for open-ended exploration. Provide blank xDesign templates and sketching materials for learners to begin ideating.

Welcome:

Welcome learners, and explain that they will design a complete automata system from scratch. Encourage learners to think about how motion can convey emotion, narrative, or theme. Review the Engineering Design Process, and explain that learners will use a blank xDesign template to create all components of their automaton, including the topper, cam or gear system, and frame. Emphasize the importance of creativity, iteration, and problem solving.

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.

Key Terms:

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

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

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

Linkages: Mechanical connections that control movement between different parts

Kinetics: The study of motion and forces affecting mechanical systems

Tolerance: The acceptable variation in dimensions for

fabrication accuracy

Note: We suggest fabricating driveshafts that are flat on one side rather than cylindrical (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.

Ideate:

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 (shape of cams, gears, etc.) needed to achieve those movements.

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 two 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: 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.

For xDesign Steps Click Here

xDesign steps can also be found:

In xDesign under Content

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 settings calibrated in XCS

Vinyl cutter: SVG files with settings calibrated in Brother CanvasWorkspace

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 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.”

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 if not (adjusting settings as necessary).

Remove workpieces and scrap stock from the machine.

Close the lid.

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 “stick” has worn off).

Position your cardstock on the paper.

Load prepared cutting mat into the machine.

Configure cut settings:

Turn off half cut.

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.

Assemble:

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 your topper 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.

Discussion Questions:

Does your automaton 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 did you apply your findings to your automaton design to achieve your desired movement and storytelling?

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 learners 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:

Learning to design and fabricate automata using CAD software, a laser cutter, vinyl cutter, and 3D printer opens up a variety of exciting career paths:

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.

These career connections highlight the versatility and applicability of the skills learned in this lesson, showing how they can be valuable in various professional fields.