SKYWORX

A toy version of a high school art class assignment. I began with a few paper models before moving to wood.

Without having access to a 3D printer, I opted for simple pivot joints. The joints use small wooden pegs that allow rotation around a single axis. They also serve as crude fasteners between limbs with the help of friction.

The legs were made as blocks without knee joints to give the model a fighting chance at standing upright. The arms include a joint at the elbow.

Parts were designed using the Siemens NX computer aided design (CAD) program. Although most of the concept work was done using pencil and paper, NX helped in several ways. Namely, it gave me the chance to view and troubleshoot the assembly prior to making each part (for example, the legs getting in the way of the arms). Range of motion and body positions could be viewed without the need for calculations. Another benefit was to try different color schemes. Perhaps most importantly, the CAD program was used to print orthographic views of each part to scale as templates, making the construction process easier.

Blocks of wood were measured and cut to overall size. The orthographic views were then printed on paper, cut-out, and pasted onto the blocks. Final cuts were made using a scroll saw, and holes were drilled using a drill press. For large parts like the torso, a table saw was used. The rocket cones strapped to his backpack were the most troublesome parts to make. They were made by making several angled passes through dowels.
Gray wood stain was applied to the head, torso, and waist. The feet, rocket cones, and boosters were painted black. Alcohol inks were used to color the limbs and rockets. The stain and alcohol inks preserve the wood grain texture which gives the toy a natural look.

Lastly, two coats of polyurethane were applied to draw-out the colors and protect the parts. This was almost a big mistake. I didn’t add much tolerance between parts, and the added thickness ate up the last of it. The parts still move and Rocket Man is still standing (Elton John, anyone?)

 

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