Sculpt, Deploy, Repeat: Fast Prototyping of Interactive Physical Objects

TL;DR

This paper presents a rapid prototyping method for interactive physical objects that combines 3D printing, sculpture, and electronics to enable quick, iterative design of functional prototypes with minimal technical barriers.

Contribution

It introduces a fluid design process that integrates sculpture and electronics, reducing time and skill requirements for creating deployable PhysiComp prototypes.

Findings

Prototypes can be created in about 4 hours of focused effort.

The process supports concurrent exploration of multiple designs.

Rapid iteration leads to quicker convergence on functional, comfortable prototypes.

Abstract

Building a deployable PhysiComp that merges form and function typically involves a significant investment of time and skill in digital electronics, 3D modeling and mechanical design. We aim to help designers quickly create prototypes by removing technical barriers in that process. Other methods for constructing PhysiComp prototypes either lack fidelity in representing shape and function or are confined to use in the studio next to a workstation, camera or projector system. Software 3D CAD tools can be used to design the shape but do not provide immediate tactile feedback on fit and feel. In this work, sculpting around 3D printed replicas of electronics combines electronics and form in a fluid design environment. The sculptures are scanned, modified for assembly and then printed on a 3D printer. Using this process, functional prototypes can be created with about 4 hours of focused effort over a day and a half with most of that time spent waiting for the 3D printer. The process lends itself to concurrent exploration of several designs and to rapid iteration. This allows the design process to converge quickly to a PhysiComp that is comfortable and useful.