Metal Structure : The Challenge is to build a small-scaled structure with metal sheets to hold up a heavy weight with the help of rivets.
AI Template 
Prototyping
From there on, i begin prototyping out my designs and see whether it works. I started out with extrusion but after consultation i realized i have to think out of the box. Hence, i went on to explore modular shapes that i can tessellate. However, the results wasn’t what i wanted to achieve. Then i thought of the gestalt principles: closure. Without actually having a hexagon plate at the bottom i manage to use 6 tower to create a hexagon outline.
Selection of 1 final design and develop it
After prototyping out various design, I've decided to develop the structure above on the left. So, after consultation i realized that my structure needed more support so that it won’t be flimsy. I’ve also realized that i might not have enough material as each of my tower is 3 cm wide and i have 6 towers in total. So there’s 2 ways to go about, one is to reduce the number of tower, two is to reduce the sizing of the tower. So I've picked option 2 and change the width to 2 cm but the length remains as 11 cm as you can see on the right.
Prototype the modified design and test it out
Finding the suitable metal tab 
After solving the structure stability for the tower structure. Now i have to find a way to connect the tower together so that they will be stronger to withstand the load when connected. Because of my small width of 2 cm each tower, i have to be precise on the metal tabs measurement. So, i went on experimenting on different sizing. Initially the first few overlapped each other which is what i do not want. Thankfully after adjusting and testing , I've managed to find the perfect metal tabs length to complement my artwork. It can be rather tricky at first as you have to take note of the angle when it bends as it will affect its length.
Making with Metal Sheets
When the template is finalized, i begin to paste it on the metal sheets and cut it out. That’s when i realized a problem, because of how thin it is, it bends when you cut. So, i decided to put weights on it overnight to treat it. Afterwards, it got slightly better and straighter then i proceed bending it according to my sketching placing.
After having all my tower frames and tower ribs manipulated at desired position. I started riveting the tower frame and the tower rib together. After all 6 towers are riveted, from there i use the metal tabs I've created and connect all 6 towers together while using the printed template as a guideline to form the hexagon shape in the middle.
Test out its structure stability
Product Photography
Class Assessment
Metal Structure supporting 5Kg
Metal Structure supporting 15 Kg
Metal Structure
Published:

Metal Structure

Published: