Practical 3

Pre-Experiment Preparation
Before we attended Practical 3 in school, we had to complete a short literature review on cardboard and its various uses and applications. After that, we had to write a brief summary of what we had learned.

Short Notes on Corrugated Fibreboard
A sheet of corrugated cardboard is made from a sheet of corrugated or “fluted” material in the centre, placed between 2 layers of paper, and held together by glue, which fixes the flutes in position and adds rigidity and stability to the papers. The flute is the “corrugated” section between the two liners, and by changing its height and therefore the size of the flutes, it is possible to achieve different performance characteristics. The liners are made of mainly Kraft paper or Test paper. The weight of the cardboard gsm is expressed in Grams per Square Meter, or gsm. An additional fluting section and additional liner can be added to make a “double wall” or “double walled” material, which adds extra rigidity and strength to the material. Depending on the thickness of the flutes, corrugated cardboard can be used in die cutting applications, packaging and shipping boxes.


Practical
For the practical session itself, we had to report to the T11C SP Fablab. After a brief introduction to cardboard, we were tasked with forming a product that consisted of the 6 joineries that we were given: Tabs, Slots + Tabs, Slots, Gusset, Flange and Score + Bend. We also had to research on and include 2 other joineries in our final product. The two other joineries that we used were cable ties and safety pins. Together, we decided that our product would be a helicopter.

Figure 1: Tabs were used in the construction of the stabiliser at the end of the helicopter

Figure 2: Slots + Tabs were used in the cockpit of the helicopter to solidify the cockpit and prevent it from flopping around

Figure 3: A Gusset was used for the air vents at the side of the helicopter

Figure 4: A Flange was used to connect the rear half of the helicopter fuselage to the main body

Figure 5: A Score + Bend was used for the main rotor assembly

Figure 6 and Figure 7: Cable ties were used to secure the back rotor blades to the stabiliser, and the missile pods to the side of the helicopter

Figure 8: A safety pin was used to secure the main rotor blades in position

We also used a lot of glue to keep the pieces of cardboard together.

Figure 9 and 10: The making of the helicopter

After the construction of the helicopter, we were to give a presentation about our product.



Post-Practical
We were asked build and complete a paper cardboard unicorn at home. It is held together using only tabs and slots, and there is no glue used in its construction.
Figure 11: Paper unicorn by Nick

We were also asked to design a mechanism that would enable the unicorn's wings to flap back and forth. This was done using a single rubber band which tied the unicorn's wings together. When pulling on the rubber band, it would cause the wings to flare out, and when released, the wings would fall back to the neutral position.

Video 1: Flapping unicorn wings

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