Fab-in-a-Box Paper Pop-Up Books: Deep Dive

Collect a few intricate pop-up books or mechanical paper models to inspire learners and spark discussion around engineering challenges. These can be sourced from your local library or online platforms like 123D for more advanced designs. Ensure that learners have access to xDesign and previous templates from the Exploration level to build upon. Encourage learners to storyboard their book spread before jumping into CAD. Prepare the Brother ScanNCut with plain cardstock, and demonstrate the loading and cutting process with the group to reinforce familiarity with the machine. Provide a variety of cardstock weights, drawing tools, and mechanical assembly materials (brads, string, hinges) to support complex builds.

Welcome:

Welcome the class, and introduce the advanced challenge: engineering a multi-layered pop-up book spread using CAD tools and vinyl cutting technology. Begin by discussing the intersection of art and engineering in paper pop-ups and how forces like pushes and pulls can be harnessed to create motion. Define key terms such as mechanism, sequencing, and layering. Briefly review the role of CAD software in prototyping and fabrication. Show examples of intricate pop-up books or mechanical paper models to inspire learners and set the stage for deeper exploration into design and engineering principles.

Context:

Pop-up books represent the pinnacle of paper engineering, where intricate mechanisms and layered designs come together to create immersive, interactive experiences. These books rely on carefully orchestrated forces, pushes, pulls, rotations, and lifts, to animate scenes and convey complex ideas. Some of the earliest pop-up texts used these techniques to engage readers and add depth to storytelling. In this advanced lesson, learners apply engineering principles to design multi-page spreads, integrating mechanical thinking with artistic vision. CAD software and vinyl cutting tools support precision and iteration, allowing students to prototype and refine their designs like real-world engineers.

Key terms:

Score Line: This line created in the material makes it easier to fold. In CAD software, score lines are typically represented differently from cut lines.

Cut Line: This is the line along which the vinyl cutter will cut the material. It defines the edges of the design.

Path Editing: A function in CAD software, this allows users to manipulate the paths or outlines of shapes and designs.

Demonstrate advanced use of the CAD software by reviewing essential tools, shapes, text, and path editing, then moving into more complex techniques, such as layering, grouping, and aligning components. Emphasize how to strategically place cut and score lines to control movement and sequencing in a multi-layered pop-up. Create a sample book spread in real time, explaining how each fold and mechanism contributes to the overall interaction. Encourage learners to ask questions, suggest ideas, and think critically about how their designs will function when assembled. Highlight how CAD tools support iteration and precision in engineering design.

For xDesign Steps Click Here

xDesign steps can also be found:

In xDesign under Content

Prepare machine:

Turn the machine on.

Connect to the machine via bluetooth or a USB cable.

Select the appropriate machine from the menu once it appears.

Note: If a firmware update is required, you will need to install this before proceeding.

Safety Note: Never leave the vinyl cutter unattended while it is running. Keep hands and other body parts away from the cutting area during operation.

Prepare material:

Using a low-adhesion mat, line up your cardstock, and press it firmly into place.

Line the mat up with the machine.

Push the arrow button to load the mat, centering it between the pressure wheels.

Use the arrow buttons to align the toolhead with the upper right corner of where you wish to cut.

Send file:

The machine will take a few moments to process your file, cutting first and then scoring.

When the machine has finished, press the unload arrow to release the cutting mat.

Post-processing:

To remove your workpiece, turn the mat over so the workpiece is flat on the table. Gently peel the mat off of the workpiece. (This helps keep your finished product flat and intact. Peeling the workpiece from the mat will likely result in torn or curled cardstock.)

Bend and crease:

Carefully bend along each mountain and valley fold in your pop-up book spread, paying close attention to how the layers interact. These folds are essential for controlling movement and ensuring the mechanisms function smoothly. Once the folds are in place, go back through with more pressure using a fingernail, scoring tool, or 3D-printed creasing aid to create sharp, reliable creases. Gently fold the entire spread flat, checking that all elements collapse and expand as intended. If you’re mounting your design to a backer or book page, glue it down with precision, aligning the center creases to maintain symmetry and function.

Decorate:

Add doodles, sequins, googly eyes, or other decorative elements!

Extensions:

Paper circuits

Appropriate for any level, no soldering required! Add copper tape, a coin cell battery, and LEDs to really bring your pop-up card to life. Consider adding a press-tab; when a copper-clad paper “button” is pressed, it completes the circuit to illuminate the bulb.

Discussion Questions:

What can you tell me about your pop-up book?

Why did you choose this design?

What difficulties did you have with CAD and the vinyl cutter?

Did you use letters, shapes, or both to create your work?

How did the connections impact your design choices?

Optional Tie-ins:

Mathematics:

Geometry and Measurement: Integrate lessons on geometric shapes, angles, and measurements. Students can apply these concepts when designing their pop-up cards, ensuring accurate dimensions and angles for the score and cut lines.

Symmetry and Patterns: Discuss symmetry and patterns in design. Students can create symmetrical designs and explore how patterns can enhance the visual appeal of their pop-up cards.

Art and Design:

Graphic Design Principles: Introduce basic graphic design principles such as balance, contrast, and color theory. Students can apply these principles to create visually appealing and effective pop-up card designs.

Creative Expression: Encourage students to express their creativity through their designs. They can incorporate personal themes, stories, or messages into their pop-up cards, making each project unique.

Engineering and Technology:

Mechanical Engineering Concepts: Explore the engineering behind pop-up mechanisms. Discuss how different types of folds and cuts can create various pop-up effects, and relate this to real-world engineering challenges.

Technology Integration: Highlight the role of technology in modern design and manufacturing. Discuss how CAD software and vinyl cutters are used in various industries, from product design to architecture.

Career Connections:

Learning to design and fabricate paper pop-ups using CAD software and a vinyl cutter opens up a variety of career paths:

Fine Arts: Artists can use CAD software to create intricate and precise designs for various art projects. The skills learned in designing and fabricating pop-up cards can be applied to creating unique, high-quality artwork and exploring new mediums.

Marketing: In marketing, the ability to design custom pop-up cards can be a valuable skill for creating engaging promotional materials and direct mail pieces. These eye-catching designs can help capture the audience’s attention and convey messages effectively.

Book Making: Bookmakers and publishers can use CAD software and vinyl cutters to design and produce interactive elements in books, such as pop-up illustrations. This adds a dynamic and engaging aspect to books, making them more appealing to readers.

Mechanical Engineering: Mechanical engineers often use CAD software to design and analyze mechanical systems. The precision and understanding of mechanisms required in creating pop-up cards can be directly applied to engineering projects, enhancing their ability to design functional and efficient systems.

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