Tutorial 2: Interdisciplinary Skin

Project Object: Lighting

Main Steps:

1. Measure the template's dimension and cut a proper aluminium sheet
2. Use the half-sphere tool to round the aluminium sheet to a half-sphere shape
3. Make the contours base on the template
4. Round the edges of the contours
5. Adjust to adhere to the template
6. Sand and polish the skin

Process:

1. Use a round aluminium sheet to start. 

Find the centre of the sheet.

 Draw the main contours to prepare for making a sphere shape.

 2. Fix the half-sphere tool on the working table.

 I am going to use this hammer to shape the aluminium sheet.

 Hit the sheet from the centre.

 Tips: the quickest way to make a sphere shape is to hit the sheet from the centre and move the sheet to the edge gradually, the way I move it is like a helix curve.

 Then put the aluminium skin on the template, it is round enough to cover the top of the template.

 3. Then draw the contours base on the template.

 Use the timber block with a diagonal plane.

 I didn't hit it quite well, but I could still see the rough shape of the lighting.

 The shape is getting better after trying to hit it in a different way.

  I change the hammers to smaller ones in order to make more details.

  This tool works well in making the edge.

  This time is getting better, however the height if each part need to be modified.

  The basic shape comes after comparing to the template and adjusting many times.

  

  4. Next step, use the pie shape tool to enhance the contours.

  Hit the skin with the hammer carefully.

  Then use the hammer with plain end (hit carefully bit by bit),

  and the tool with a rounded edge to round the contours.

Compare to the template to get a perfect shape.

 5 & 6. When I get a satisfying shape I use the methylated spirits to clear the marks on the skin. 

Make adjustment if needed.

Finally cut the rough parts off,

 and sand the edge of the skin.

The skin of lighting is finished.

It perfectly adhere to the template and looks good.