2. Project Overview Introduction & Product Analysis
Drawing & communication
Sensing abilities in robots
Programming Robots
Mechanisms and Systems
Designing new products & Packaging
Presentation and Rendering
Biomimicry
Concept Modelling
Concept presentations

3. LESSON 09

4. LESSON 9 STARTER
Learning objective: Be able to use a range of tools, materials and processes to create a unique concept model or prototype. Explore design solutions in 3D using craft materials. Develop an understanding of how products develop.
QUICK STARTER TASK: Take a Nano between two, and quickly turn it into another insect of creature using card, polystyrene, lollipop sticks and other craft materials. Use a hot glue gun to stick parts to the rubber part of the Nano only (for easy removal after). You have 5 minutes!

5. LESSON 9 STARTER
Share with the class what you have made Here are a few models made by other pupils aged 11 years olds Present yours quick to the group (a nano 15 second presentation) explaining what features you added and why.

6. A look in detail at model making
What is model making?
Model making is often associated with hobbyists, who might make model trains or war game figures to enjoy at home. In the design industry, model making is a highly specialised and informative stage of the design process. It provides opportunity for a design team to take their 2D ideas, and turn them into a physical 3D model. When modelling began on the Nano, there was a need to explore different plastics and rubber in the models, to create the “spring” in the insects movement. Whilst plastic is a little harder to work with, the whole model could have been made in card and straws initially.
Plastic
Rubber
New words: hobbyist, industry, 2D, 3D, spring, model, rubber

7. A look in detail at model making
Model making Is a skilled process. Whilst anyone can make models, model makers are individuals who practice these skills (much like a sportsman would) and make professional quality models for a living. Modelling materials can range from card to foam, to plastic and clay.
This Hexbug original was an early model to test how the legs would move together. It is made from plastic parts.
Early Hexbug ant models using 3D printed parts to test out the movement of the legs.
Where there is complex movement or geometry, computer aided design (CAD) can be used to test and animate. This is the scarab as a CAD model.

8. How to concept model ideas
Why concept model? Here are two working models (prototypes) of Hexbugs, a crab and an inchworm. These models both have moving parts. They both have no colour or detail.
Question Why make a model? Why produce a testable 3D product? Why not simply go straight to mass production?

9. How to concept model ideas
The purpose of making models These developing models exemplify the reason why concept modelling is a key step in the design process. It allows ideas to improve by testing each model as they are made.
IMPROVING DESIGN
IMPROVING DESIGN
Final Nano

10. How to concept model ideas
Working with craft materials Corrugated and plain thick card are ideal modelling materials to use. They are simple and quick to cut with scissors or a craft knife, they glue easily or can be taped. Card is also easy to hole punch, bend, tear and score. Foam, such as blue foam, is used as insulation in the building industry, but is a perfect material to shape and carve. This can be done with sharp knives or abrasive papers like sand paper. Polystyrene boards, balls and packaging is also just as useful to work with, though can crumble into chunks if not shaped carefully. Sticks and pegs made from wood or plastic, and other similar items like straws and wires are ideal for features such as antenna or legs.

11. How to concept model ideas
Designing your idea in three steps Step 1: Create a quick brainstorm of all the different types of small creatures and insects that have yet to be, but could be, turned into a Hexbug robotic toy. Try to be unconstrained by thinking of what you can and cannot make, and simply focus on ideas. Step 2: Now think back to the lesson on sensors. Think of all the sensing capabilities a robot toy can have. Think of what characteristics your new Hexbug ideas could have and add these onto your brainstorm. Step 3: Now it is time to design your Hexbug. Select one of your ideas, don’t forget the sensors, and start sketching your ideas.

12. How to concept model ideas
Make your Model Task: To make a small box for the motor and circuit of your Hexbug, cut thin polystyrene sheet or corrugated card into rectangular pieces, then using a glue gun along the edges, stick them together into a box shape. Here are three photos of the three steps.
Safety warning If you are using a craft knife, you must use a safety matt and safety ruler, and when using, always cut away from your hand.

13. How to concept model ideas
Making Skills To create some features you can use these techniques:
Use card and split pins to create wings, shells and outer body parts in colourful card. Split pins allow parts to hinge and move.
When cutting multiply matching parts, use the first as a template for the second and third, so that they are all the same.
Using thin card you can bend, cut and colour all sorts of parts and designs, so don’t feel restricted with such simple materials.

14. How to concept model ideas
Example modes and what they do… Now that you have designed your own unique Hexbug model, here are some examples made by pupils you could take inspiration from. 1. Woodlouse – wheels around but curls up into a ball when it senses sound, and rolls away.
The yellow antenna are triggers to the Hexbug Louse.
Shown above is the shell that closes around the insect and turns it into a ball.
At the back there is the on off switch and the sound sensor to trigger the bug.

15. How to concept model ideas
Example modes and what they do… 2. Scorpion – crawls around using its legs and wheels, but when its front antenna are touched, the tail strikes and it scurries away.
The Hexbug Scorpion can wheel around but also has legs to keep it stable and insect like. When the front antenna are triggered, it strikes!
On three wheels, two at the back and one at the front, it can move around anywhere or run away quickly to a safe place once it strikes.

16. LESSON 9 PLENARY
As a class, let us consider the following questions? A. Why do we use corrugated card to make models? What characteristics does it have?
B. Why are models better for a cost conscious design company than making final products first?
C. How have we made you models move?
D. What might be the next stage of development for your model to improve it?

17. Summary Today you have:
Learning objective: Be able to use a range of tools, materials and processes to create a unique concept model or prototype. Explore design solutions in 3D using craft materials. Develop an understanding of how products develop.
Today you have:
Learnt how to use different tools and materials to make a concept Hexbug.
Explored your own 2D designs and turned them into 3D models.
Learnt how designers use model making to help them develop a product towards a final solution.