Lesson video

Hi there and welcome to your design and technology lesson for today.

My name is Mr. Booth.

Thank you so much for joining me.

Today's lesson is all about cardboard modeling techniques.

If we are gonna create successful prototypes and develop our ideas really well, we need to be able to model in cardboard.

And to do this, we are gonna go through a lesson where you're gonna learn lots of new skills on how to use cardboard to make 3D prototypes.

This lesson forms part of the ergonomic design, accessible controllers unit, where we are trying to design controllers that are more accessible to people.

Today's outcome: You are gonna use cardboard modeling to develop ideas.

It's as simple as that.

Let's have a look at our four keywords for today.

So the first one is prototype.

Now, a prototype is a simple, low-cost model that we make to check the size, the shape, the function, and often many other aspects of a design.

To make prototypes, one of the number one materials we can make them out of is corrugated cardboard.

And corrugated cardboard is cardboard with a fluted layer to increase strength and rigidity.

Now, that fluted layer we call fluting is the wavy layer in the middle of the two layers of cardboard.

And then finally, of course, we're gonna have to stick all this together.

And for that, we use an adhesive.

And this is a substance used to bond materials through a chemical reaction.

We have two learning cycles today.

The first one is prototyping, and then we have some more complex cardboard modeling techniques in the second learning cycle.

So let's get on with the first learning cycle.

So cardboard is a thick, strong paper material made from layers of wood pulp.

It's often used for packaging, and I'm sure you often get packages through the post that are wrapped or contained within cardboard.

But we also use it for crafts and creating prototypes, mainly because it's strong, it's rigid, it's light, and it's really easy for us to shape, to cut, and to fold, and to create into different shapes.

There are some different types of cardboard.

We have corrugated cardboard.

We have paper board, greyboard, and also honeycomb board.

Now, you might have come into contact with all of these.

So what is cardboard made of? Here's a quick check for understanding.

Is it a: layers of wood pulp, b: polymer granules, or c: glass reinforced fiber? Pause the video now, have a go at this, and come back to me when you've got your answer.

It is, of course, layers of wood pulp, well done.

Let's have a closer look at corrugated cardboard.

So we know it's used in prototyping due to its structural integrity, its strength, and its versatility.

But where does it get that integrity and its strength from? Well, it has two layers from the outside and the inside, and then it has this fluted layer in between.

And that fluted layer is the key to making cardboard strong.

The arches that you can see on the diagram here spread out the weight and the pressure, making the material stronger than just card on its own.

Now, there are two very common designs for corrugated cardboard used, and you've probably had products delivered through the post using both of these types.

The first one is what we call single-walled, and that's very obvious in the fact it has one layer of fluting in between the two flat sheets either side.

And this is used for everyday packaging.

But we also have double-walled.

You can even get triple-walled as well.

Now, this has two layers of fluting with three flat sheets sandwiched between there.

Now, this is used for heavier items or when an item needs extra protection.

Now, we use both of these for modeling, and sometimes using the double-walled can improve the rigidity of your models.

But just remember, it's a little bit harder to work with.

So let's have a quick recap.

Corrugated cardboard is used to make prototypes because it's cheap and readily available.

Like I said, quite often it's delivered through the post and it's almost like it's free.

We usually recycle it, but actually, we can use it for making prototypes.

It's strong and it's rigid, and we've seen that because of the fluted layer in between.

It's easy to cut and shape and great for trying out ideas quickly to create 3D models of prototypes.

It's lightweight, so it's not gonna be heavy when we're using it.

And once we've finished making our prototypes, of course, we can recycle it or sometimes even break it down and use it for other prototypes.

Quick check for understanding.

This image shows single-wall corrugated cardboard.

What are parts A, B, and C called? Pause the video now, have a go at this, come back to me when you've got your answer.

So part A is the outer liner, part B is the fluted layer or the fluting in between, and then, of course, we have the inner liner as well.

Well done.

So what we're gonna look at now is how to create a really simple corrugated cardboard model for an ergonomic controller.

And then you're gonna have a go at this as well to improve your skills of using cardboard, but also of modeling ergonomic controllers.

So first of all, we're gonna limit ourselves with the amount of corrugated cardboard we're gonna use.

Yes, it's readily available, but what we don't wanna do is use too much.

We want to make sure we use the right amount of materials.

So we're gonna start with a pice of single-walled, so this is a single-layered corrugated cardboard.

And what we're gonna do is we're gonna use roughly a piece 150 millimeters by 100 millimeters.

What we're then going to do is pick up the material and interact with it.

It's really important that we have physical connections with the materials that we use in design and technology.

And for this, because we are designing an ergonomic controller, it's important we pick it up with our hands and hold that material before we start modeling.

So how far can your fingers reach? Where do your fingers go? Which pieces feel uncomfortable, and what already feels comfortable? Is it comfortable to hold? Probably not at the moment, so what we're gonna do is we're gonna start shaping it.

Next, we're gonna mark with a pencil where we think the buttons would best fit for us.

So we're gonna look at where our thumbs are and possibly even where our fingers are.

So you need to find out where your thumbs and your fingers reach.

We're then gonna mark the outside shape.

What's gonna be the most comfortable to hold? Certainly holding a rectangle of cardboard isn't gonna be comfortable to hold if you are imagining you're using a games controller.

So think about comfort and reach again.

We're then gonna continue to mark around the whole of the controller.

So on the top and the bottom, thinking about the shape that we think we're gonna use to make it the most ergonomic design we can.

And then what we're gonna do is we're gonna cut the shape.

Now, if you're cutting curves in cardboard, often, scissors are the easiest way to do this.

Once we've done that, we're then gonna test the shape of our new model and make any adjustments that we need to do based on what it already looks like.

And then finally, try cutting out or marking some buttons or triggers onto your model.

You can be really creative with this.

You might wanna add some color as well to mark out where you think they need to go.

So we're now onto your first task, and as you guessed it, you're gonna have a go at what I have just explained.

I want you to create a simple corrugated cardboard prototype of an ergonomic games controller.

There is a little bit of a success criteria this as well.

The first thing, let's use as little material as possible.

So we're gonna use a piece of corrugated cardboard roughly 150 millimeters by 100 millimeters.

Your model should be ergonomic and fit your hands.

This is for you.

I want you also to include buttons and triggers for where you think they will be comfortable.

Pause the video now, have a go at this, and come back to me when you've completed your models.

So how did you get on? Well, I'm sure you've created some absolutely fantastic ergonomic controllers.

And they might have looked like these.

Well done with that task.

So we're now onto our second learning cycle.

And in this learning cycle, I'm gonna teach you some more skills and techniques that you can use with cardboard modeling, which will really help you with your prototyping in the future.

Corrugated cardboard can be layered, slotted, joined, and folded together to build strong and functioning 3D prototypes.

Now, when I say functioning, I don't mean that you're gonna plug your cardboard controllers into a computer and start moving characters on the screen.

Obviously that isn't possible.

But you might have buttons that might move and interact with the users so they can test where those buttons are gonna be.

Now, companies such as IKEA use corrugated cardboard to model furniture before making the real versions, even life-sized furniture.

Nike often create early shoe models with corrugated cardboard and even paper.

And automotive companies, such as Ford and Toyota, the two biggest manufacturers in the world, use corrugated cardboard to mock up car interiors and even some parts.

So you can see there some of the most famous manufacturers in the world use corrugated cardboard on a daily basis when they are prototyping.

Now, when modeling with corrugated cardboard, we're gonna have to use adhesives.

So we've gotta think carefully about which adhesives to use.

Now, polyvinyl acetate, or you might know this as PVA, is a white, liquid adhesive used for bonding paper, cardboard, and even wood.

Now, the great thing about PVA is it dries clear and it's really easy to clean up.

You can even get quick-drying PVAs, which is fantastic for modeling.

So if you can your hands on some of that, that's even better for creating prototypes.

You might have also come across hot melt adhesives that can be used with hot glue guns or sometimes quite confusingly called cool melt glue guns.

Now, these adhesive dry very quickly.

They dry rapidly in seconds.

They can even fill small gaps between spaces, so they're really good for that.

But they can look unsightly, and they tend to be more expensive.

But let's just have a look at a hot melt glue gun.

So a glue gun uses heat to melt the stick adhesives.

When the trigger is pulled, the stick is forced through a heating element, it becomes a liquid, and the soft glue is extruded through the nozzle at the end to where you want it.

And then, of course, it bonds your two pieces of cardboard together.

And yours might look something similar to this.

So there is our glue stick in its solid form.

It has a feeder, which is connected to the trigger.

It then goes through a heating element, and it comes out of the nozzle.

Now of course, the nozzle, you should never touch, even if you think the glue gun is cool.

So which of the following adhesives could you use when joining cardboard to make your prototypes? We have a: epoxy resin, b: PVA, and c: hot melt glue.

Pause the video now, have a go at this, and come back to me when you've got your answer.

It is, of course, PVA and hot melt glue, with PVA probably being the preference if you've got a bit more time, 'cause it's a bit neater.

We're now gonna look at how we can join cardboard together to create a variety of different shapes.

And the first one we're gonna do is just create a straight join at 90 degrees between two pieces of cardboard.

Now, you're gonna need all your usual modeling materials.

But you also are gonna need a craft knife, a safety rule, and also a cutting mat.

Now, the first thing we're gonna do is we're gonna line up the safety rule on a flat piece of cardboard and also our upright piece to mark where we're gonna make a cut.

So you can see it's right on the edge here.

This next image shows it a little bit better.

What we're then gonna do is using a safety rule and also the craft knives, we're gonna cut through the outer liner and the fluted layer, leaving the inner liner uncut and intact at the bottom.

Once we've done that, we can use a steel ruler, and I'm using a 150-millimeter steel ruler in this case, 'cause I find that a little bit easier to handle.

And what we're doing is removing the outer liner and the fluting layer that we've just cut through.

We're gonna leave the inner layer intact, and that should be at the bottom.

And you can see on the little image there, I've zoomed in on that to show you what it should look like.

Now again, if you make a mistake, don't worry about it.

This is actually a quite complicated skill to learn, but once you've got it, you will find it very easy.

What we then do is we then apply our PVA to the exposed inner liner.

You'll see you've actually got a little gap to apply the glue to.

Also notice on the image, I'm using some scrap cardboard underneath my design, because I don't want to get PVA all over my cutting mat.

Once we've done that, we can bring our other piece back in, line up both pieces, and create almost a lap joint using cardboard.

We then need to check the joint for accuracy and probably apply masking tape while it dries.

Now, you'll notice a few things on that final image.

Number one, you can't see the fluted layer because we've covered it up by creating almost that lap joint.

And what that does is that not only makes our models look more aesthetically pleasing, but it also increases the strength of our models.

They're not going to fall apart.

We could, of course, just have created a butt joint without cutting the fluted layer out.

But actually, this is far stronger, and I think it looks better as well.

So now you've seen all that, what is this image showing? Is it a: applying adhesive to the outer liner and fluted layer? Is it b: removing the outer liner and fluted layer? Or is it c: cutting the outer liner and fluted layer? Pause the video now, have a good luck at the image, and come back to me when you've got your answer.

It is, of course, b.

I'm removing the outer liner and fluted layer.

I've already cut through them with a craft knife, and I'm using my steel rule to remove them.

Well done.

So quite often, you need to create a curved join as well.

We're not just gonna be able to make prototypes with straight edges.

We need to create curves as well.

We're gonna use a lot of the skills we've just learned, but we also have some other tricks that we need to do.

So first of all, we need two pieces of cardboard again.

And on the first piece of cardboard, we're gonna draw and cut a curve.

Now, you can see in this image, I've used a compass to make sure it's nice and neat and then I'm just gonna cut it with a pair of scissors.

The second piece of cardboard needs to be long enough so it can travel round the entire curve that I've just created.

So you might need to measure that.

What I'm also gonna do then is use a biro, and I'm intentionally damaging the outer liner along that fluted layer.

The biro will follow the fluted layer as you draw from the top to the bottom, and you're trying to break through that outer liner.

And what that will do is that will then allow us to curve the material nice and neatly, as you can see on the zoomed in image.

What we're then gonna do is repeat what we did last time.

We're gonna line up our designs, our two pieces of cardboard, and then we're going to use a craft knife, cut through the outer liner and the fluting, and then again remove that edge using a steel rule.

Once we've done all that, we're then gonna apply the PVA, just as we did before, line up both pieces, and then roll the longer piece around the curve until it covers the entire curve that you've just created.

Once again, check it for accuracy, apply some masking tape while it dries.

And you can see there, we've got a really nice, neat curve.

And again, once again, because we're created almost a lap joint, it's nice and strong as well.

So quick check for understanding.

Why do we intentionally damage the outer liner of corrugated cardboard along the fluted layer when creating curves? Is it a: to increase the strength? Is it b: to create a smooth curve? Or is it c: to reduce the weight of the final prototype? Pause the video now, have a good look at the image, and come back to me when you've got an answer.

It is, of course, to create a smooth curve.

Creating that kind of lap joint increases strength, but the reason we damage that fluted layer is 'cause it gives us a nice smooth curve on the outer side of our corrugated cardboard.

Well done.

We can also do other things as well.

We can layer corrugated cardboard to add depth to a prototype.

So what we can do is stack and glue layers of material on top of each other.

Each layer can be the same size, or you can even shape them differently.

You can make them get bigger or get smaller and build a thickness to create a 3D effect.

And that's really successful when you're trying to build depth to your prototypes.

We can also fold to create movement in a prototype.

And you might wanna use this in your accessible controllers, because of course, you've got buttons and joysticks.

So first of all, we're gonna start with a strip of material.

And we're gonna draw on some 10-millimeter lines using a rule.

We're then gonna score those very carefully, again using a steel rule and the back of a pair of scissors.

Now again, make sure you've got a cutting mat, but what that will allow is that will allow the cardboard to fold up in a zigzag.

We can decide how high we want that button to be, 'cause that's what we're creating in this, by cutting off the excess.

And then, of course, you can glue that onto your controller, and what you've got there is you've got a little joystick, which will move around, so you can interact with it with your thumbs and fingers.

Onto task B, your final task for today.

And you're gonna get a bit of time to do this task.

So the first thing I want you to do is using scrap cardboard, I want you to practice creating straight joins and curved joins using the corrugated cardboard modeling techniques we've just gone through.

I then want you again to use scrap corrugated cardboard, and I want you to practice creating 3D shapes using the layering technique.

And then finally, I want you to manufacture a move stick for your corrugated cardboard games controller prototype using the folding techniques.

I hope you really enjoy this task.

Have a go at it and come back to me when you've completed that.

So how did you get on? Well, hopefully, you've created some straight joins and some curved joins.

And again, it's absolutely fine to make mistakes.

Remember, these are prototypes.

They're meant to be quick mock-ups of your designs so you can get a real feel for if they are working or not.

Hopefully you also did some layering techniques.

And then finally, hopefully you used the folding technique to make parts move as well.

Well done with all of that.

And that brings us to the end of this lesson.

So let's have a quick summary.

Cardboard is a thick, strong paper material made from layers of wood pulp.

Cardboard is often used for packaging, crafts, and creating prototypes because it is strong, rigid, light, and easy to cut and fold.

Corrugated cardboard is used for prototypes due to its structural integrity, strength, and versatility.

Cardboard can be layered, slotted, folded, scored, and joined to build strong 3D models and prototypes.

And when modeling with cardboard, adhesives need to be used, most commonly, PVA and hot melt glue.

Well done today.

You've been absolutely fantastic.

I look forward to seeing you all next time.

Goodbye.