3. Circular Open Source Fashion

Research and Inspiration

To start the Circular Open Source Fashion week project, I explored the concept of modular joints in textiles and fabrics. I looked into different projects that used modular designs to turn flat materials into creative and functional shapes. These designs ranged from fashion pieces to home decor and even architectural structures. Seeing how simple shapes like hexagons and triangles could be connected to create something much bigger inspired me to experiment with similar ideas.

I also came across open-source fashion projects, where people shared their patterns and instructions for others to use and adapt. This idea of collaboration and creativity really resonated with me. It felt like a great way to make designs more accessible while encouraging innovation.

As I explored different modular structures, I also came across Truchet patterns, which are simple geometric tiling systems that create intricate visual effects. These patterns have been widely used in both mathematical art and design. Inspired by this resource on Truchet patterns, I decided to incorporate a similar approach into my modules by engraving these patterns onto the hexagonal pieces.

Additionally, I was inspired by Barbara Rakovska’s work in Fabricademy, particularly her Honeycomb Top. Her exploration of modular fashion using interlocking pieces reinforced the idea that such structures could be used beyond decorative applications and could serve as functional, wearable, or adaptable design elements.

Some of the key takeaways from this research included:

• Sustainability: The idea of using old or discarded materials, like tote bags, fit perfectly with my interest in reusing and repurposing items.

• Creativity and Play: Modular designs allow for endless possibilities, making them fun to build and experiment with.

• Flexibility: These systems can work for all kinds of users, from kids assembling simple shapes to adults creating complex designs.

This research gave me a solid foundation and clear direction for my project. I was excited to start prototyping and see how these ideas could come to life in my own work.

Prototyping with Paper

Once I had a clear direction from my research, I started prototyping with paper to test out my ideas. I created a simple hexagon design in Rhino and duplicated it to create a grid of hexagons. This design was then exported to the Trotec laser cutter, where I cut the hexagons from standard paper.

With the hexagons ready, I began experimenting by making additional cuts and slits using scissors. This hands-on process allowed me to quickly test different ways the hexagons could be joined together. I played around with various configurations, trying to figure out how the pieces could interlock securely while remaining flexible.

After some trial and error, I arrived at two working prototypes for the joints. These prototypes showed potential but needed further refinement to improve their functionality and ease of assembly. This initial phase of prototyping gave me a rough idea of what I wanted to achieve and set the stage for the next steps in the design process.

Parametric Design in Fusion 360

After experimenting with paper prototypes, I transitioned to digital design using Fusion 360. I started with a simple sketch of a hexagon as the base module. To enhance the design, I incorporated Truchet patterns onto the modules for engraving, adding a distinct aesthetic while preserving the flexibility of the interlocking system. Truchet patterns work well with modular designs as they create variations in visual texture while maintaining symmetry across connected pieces.

Next, I sketched two different types of joints to explore how the modules could connect. Using Fusion 360's parametric tools, I incorporated parameters into the design, allowing me to easily adjust dimensions such as the size of the hexagons and the spacing of the joints. This adaptability made the design easy to modify for different material properties and applications.

This parametric approach ensured precision and flexibility, which were crucial for testing and refining the modular system. It also set the foundation for efficiently preparing the design for laser cutting and future adjustments.

Preparing Files and Laser Cutting

After finalizing the parametric design in Fusion 360, I exported the hexagon module as a DXF file and imported it into Rhino for further preparation. In Rhino, I organized and nested the modules efficiently to minimize material waste. I also assigned colors to differentiate cutting and engraving paths: red for cutting lines and blue for engraved areas, such as the truchet pattern.

The material for the project consisted of old tote bags from my school years, aligning with the theme of sustainability. To prepare the bags for laser cutting, I carefully opened them by cutting the stitching along the seams to create flat pieces of fabric. These pieces were then secured to the laser bed using tape and weights to ensure they remained flat and stable during cutting.

Before cutting multiple modules, I performed a series of test cuts using a single module. This allowed me to fine-tune the laser's power and speed settings to suit the thickness and texture of the tote bag material. Once the optimal settings were determined, I proceeded to cut a larger batch of modules.

Initially, the plan was to engrave the Truchet pattern onto the hexagonal modules to enhance their visual appeal. However, before cutting the full set, I tested the engraving on the tote bag fabric and found that the material did not respond well. The engraving results were inconsistent, with some areas barely visible and others causing unwanted burns. Due to this, I decided to proceed without the engraving and focus purely on the cut structure.

Another advantage of using hexagonal modules was their efficiency in material usage. Hexagons allow for compact nesting, meaning very little material is wasted during the laser cutting process. This was particularly useful given the limited size of the tote bags, ensuring I could maximize the number of modules per sheet of fabric.

Laser Cutting Settings

To achieve precise and clean cuts, I performed test runs using a single module before cutting the full batch. The optimal settings for the Trotec laser cutter on tote bag material were: - Power: 80% - Speed: 50mm/s - Frequency: 1000 Hz

These settings ensured that the material was cut cleanly without excessive burning or fraying at the edges. Once the settings were dialed in, I proceeded to cut multiple modules for the final assembly.

The cut modules were assembled and tested to evaluate the fit and stability of the joints. The initial results were promising, with only minor adjustments needed. Specifically, I increased the length of some slits to improve the ease of assembly and ensure a more secure connection. These small refinements resulted in modules that were both functional and visually appealing, ready for the next phase of the project.

Assembly of Lamp

During the project, I came across an old lamp base and decided it would be a great opportunity to create a custom lamp shade using the modular hexagon system. To start, I cut multiple modules in different colors from the prepared tote bag material. The variety of colors added an appealing visual element to the design.

I began assembling the modules by connecting them with small connector pieces. These connectors were a bit tricky to handle due to their size, but using tweezers made the process much easier and more precise. As the lamp shade started taking shape, I needed to find a way to securely attach it to the metal ring structure of the lamp base. To solve this, I designed a special hexagon module with a flap that could loop around the ring and lock into itself. This design allowed for a secure and adjustable connection.

Once the new modules were designed, I cut them in various colors and incorporated them into the lamp shade assembly. The final lamp shade turned out beautifully, with the different colors glowing warmly when the light was turned on. One of the best features of the design is its flexibility—by swapping out modules, the shade’s appearance can be easily changed to create new patterns or color combinations.

This phase of the project highlighted the versatility of the modular system and its potential for creative, functional applications in everyday objects.

Exploration of Puzzle Designs

After completing the lamp shade, I began thinking about how the modular system could be used in other creative ways. The idea of transforming the modules into a creative kit for children or adults seemed like a natural next step. This kit could serve as both an educational tool and a fun, hands-on activity that encourages imagination and problem-solving.

To explore this idea, I started by creating a hexagon grid in Rhino. Using the grid as a reference, I designed various shapes and patterns, including animals like a bee, an owl, and a butterfly, as well as a flower. I assigned colors to the hexagons based on the materials I had available from the tote bags, ensuring the designs could be replicated with the cut pieces.

Next, I cut additional modules from tote bags in the required colors and began assembling them according to the reference designs I had created in Rhino. The process of connecting the pieces brought the shapes to life, showcasing the potential of the modular system to create diverse and visually appealing designs.

The concept behind this kit is to provide users with a variety of pieces in different colors, allowing them to connect and experiment freely, building their own designs or following predefined patterns. While the system is highly engaging and encourages creativity, I noticed that the small size of the joints requires significant precision to assemble. For children, this could be frustrating, so if the kit were redesigned for younger users, I would consider increasing the size of the joints to make them easier to handle.

Despite this challenge, the assembly process has a therapeutic quality, as it requires focus and coordination. This exploration phase reinforced the versatility of the modular system and its potential as a tool for fostering creativity and learning across different age groups.

Final Outcomes and Future Directions

Reflecting on the completed projects, I am pleased with the outcomes of both the lamp shade and the modular puzzles. The lamp shade demonstrated the aesthetic and functional potential of the modules, while the puzzles explored their versatility as a creative and educational tool. Both applications highlight the modular system's ability to transform simple materials into dynamic and engaging designs.

One of the most exciting aspects of the modular system is its potential as a kit for children or adults. The modules encourage creativity by allowing users to experiment with different connections, colors, and patterns. Assembling the pieces also promotes hand-eye coordination and provides a sense of accomplishment when a design is completed. Additionally, the small size of the joints and the precision required for assembly give the process a therapeutic quality, fostering focus and patience.

However, if the system were to be adapted for younger children, I would consider redesigning the joints to be larger and more user-friendly. While the current design is manageable with tools like tweezers, a larger joint would make the kit more accessible and reduce potential frustration for smaller hands.

Looking ahead, I see many possibilities for this modular system. It could be developed further into a creative kit with pre-defined designs for users to follow or as an open-ended tool for exploration. Beyond educational and recreational uses, the modules could also inspire applications in sustainable fashion, home decor, or even architectural design. The adaptability of the system opens the door to countless opportunities for innovation.

This project has been a valuable exploration of modular design, and I am excited to continue developing it and discovering new ways to expand its applications.

Files

• Modules DXF
• Modules Puzzle