Week 2: Summer Internship

This week I continued working on 3D asset creation. My basic approach so far has been to start with a simplified geometry from Fusion 360, then export that design as an .FBX (Autodesk Maya file format), import the FBX to Blender for UV mapping, material, and motion rigging. There’s probably a more streamline way to generate this content, but from a feasibility standpoint, this approach allows me to be flexible and to use different tools for discrete tasks. This week I will be importing these combined assets into Unreal Engine.

This week was also my final week for the term at PCC, where I have enrolled in their online course for Advanced Fusion 360. I’ve been working on a group project, and designing assemblies for use in a solar projector system. The design is based on COTS (commercial off-the-self parts), which required me to draft profiles to meet engineering specifications.

Picatinny rail specification downloaded from wiki-commons.

The final deliverables are due this coming Saturday, and there is still a good bit of work to be done before we get graded on this project. Nevertheless, I am very pleased with the current state of things. I’ve been using Quixel Mixer to produce more realistic rendering material than the library included with Fusion 360. I say, “more” realistic because Fusion 360 already has some excellent materials. Take a look at this rendering of a Bushnell 10x42 monocle (one of the components in this project):

I haven’t yet added any details, but as you can see, the rubberized exterior and textured plastic hardware are fairly convincing. Now, take a look at the mounting hardware rendered with Quixel textures:

An important component in photorealism is the inclusion of flaws. Real life objects are never perfectly clean, perfectly smooth, or with perfect edges. Surface defects, dirt, scratches, and optical effects play an important role in tricking the eye into believing a rendering. With Quixel Mixer, it is possible to quickly generate customized materials. While this product is intended for use with Unreal Engine and other real-time applications, it does an amazing job when coupled with a physical based renderer.

Picatinny rail set with hardware and bracket.

I’m excited to see what can be done with these materials in a real-time engine, especially given the advanced features of Unreal Engine 5. Fusion 360’s rendering is CPU driven, whereas Unreal is GPU accelerated. With both Nvidia and AMD now selling GPUs with built-in raytracing support, it won’t be long before we see applications that offer simultaneous photorealism rendering within modeling workflows.

Additionally, GPUs also work extremely well as massively parallel computing units, ideal for physical simulations. This opens up all kinds of possibilities for real-time simulated stress testing and destructive testing. It wasn’t that long ago that that ASCI Red was the pinnacle of physical simulation via supercomputer. Today, comparable systems can be purchased for less than $2,000.

Of course, this price assumes you can buy the hardware retail. The current chip shortage has inflated prices more than 200% above MSRP. Fortunately, with crypto markets in decline and businesses reopening as vaccination rates exceed 50% in some regions, there are rays of hope for raytracing-capable hardware being in hand soon.

Kinetic-friendly spoon project Mega Post

That’s a wrap! It’s certainly been an interesting semester, but now I am ready to put it behind me. Reflecting on the spoon project, I have some final thoughts and observations. First, I want to thank the fine folks at CMU School of Design. From the amazing and hardworking faculty and graduate student cohort, I have had nothing less than inspiration and encouragement throughout this entire process, despite the obvious challenges of working remotely.

Rendering of sixth and final (?) spoon design. I pulled the kitchen design (Pierre Gilles) and bowl (Damogran Labs) from GrabCad.com. The spoon and coffee mug are mine.

This project was divided into two parts: the first part focused on exploring different ways of prototyping and making. This was described to me as an informal way of A/B Testing for methods. The second part involved the deliberate iteration of prototypes through user testing — a challenge in the context of a global pandemic and social distancing. To make the most meaningful design choices possible given limited resources, I decided to leverage the power of physical simulation to supplement the making of physical prototypes.

There are a variety of 3D software tools that offer some degree of physical simulation. For this project, I selected Maxon Cinema 4D R20 (Educational License) and Blender as my two ways of making. I chose these because I already am familiar with Cinema 4D and understand know how to manage a workflow in that context, because Blender is open source and free for anyone to use, and both programs work under MacOS and Windows environments (my rendering workstation is a Hackintosh with multiple operating systems, which grants the flexibility to overcome certain technical limitations). My initial experiments with Cinema 4D were… not great.

My very first (and failed) attempt to simulate fluids in Cinema 4D. Carnegie Mellon University School of Design Prototyping for Interaction Spring 2020

As you can see, there are “physics” happening here, but they are not anything close to the physics of the real world. This is not “real world” physics, this is Asshole Physics:

Zachary "Spokker Jones" Gutierrez and I came up with the term "Asshole Physics" when we were discussing the game and the physics models it employed. Basically there's a lot of crap you can knock over and kick around, including dead bodies, buckets, cans, and little sections of drywall which are standing around in the middle of rooms for no obvious reason. Zachary casually mentioned, "I have made it a point to knock over every fucking thing in that game. I am living out my fantasies of being a giant asshole," and I responded by stealing his "asshole" comment and claiming that I made it up. Thus "Asshole Physics" was born.

Without more sophisticated plugins to simulate fluid, Cinema 4D R20 is only “out of the box” capable of non-newtonian semisolids. I can make stuff bump around and “squish.” I can have a 3D character micturating on the side of a building. I can create the appearance and illusion of something like a fluid, but with such restrictions, I could not realistically evaluate my spoon designs. I explored my options and found that Next Limit’s RealFlow plugin would meet my basic needs. Best of all, they offer a free 30-day trial! My initial excitement quickly waned after the plugin failed to install and activate on my system…

(This email chain is long and covers a week of back and forth with customer service. I am including the entire conversation as a way to recreate my experience. While this may not directly relate to the scope of this project, I still believe that there is value in documenting the unexpected problems that crop up when trying to do something new.)

It took a week to finally get everything sorted with the demo. During that time, I began to explore option B: Blender.

Blender is a free, powerful, open source 3D creation tool. Best of all, it includes the mantaflow fluid simulation engine (since version 2.8). I have worked with Cinema 4D on other projects, and have become fairly comfortable with the interface. Given my experience with Fusion 360, Inventor, and C4D, I knew that I would need to overcome a learning curve before I could use this software to meet my needs for this project. Fortunately, I was able to find a spectacular tutorial series for beginners.

If you want to read more about my experience with the tutorial, click here.

This tutorial was ideal because it involved exercises that helped me learn how to use the interface, and covered several different workflows. I was really impressed with Blender’s node-based material system and procedural textures. You can work strictly with parametric modeling, or you can discretely modify mesh geometry to create highly organic and imperfect forms. I’m excited to work with Blender on future projects. It’s a very exciting time to be working in 3D.

While working through these tutorials, I began sketching and working in Fusion 360 to craft my first spoon designs for part 2 of this project. You can read more about this experience here.

Takeaways from Part 1

I really appreciated the responsiveness from the team at Next Limit. Clearly there are problems with the software’s implementation of their product’s copy protection. This is an all-too-common problem in the world of software. Programmers gotta eat just like everybody else, and we certainly should make sure that the talented and hardworking folks behind the code are able to put food on their table at the end of the day. Piracy can deprive a small business of the necessary revenue to keep the lights on, so I am absolutely sympathetic to this reality and what risks are involved when you release your software for demo purposes. Getting people to pay for something that they can easily get for free is a challenging proposition. At the same time, you cannot realistically expect to get customers to pay for software if they cannot try it first. Ultimately, this one week of back and forth with customer support was a critical loss. I never completed a side-by-side comparison of fluid simulations. While I did eventually succeed at installing and using RealFlow to do fluid simulations, (and was honestly impressed with how easy it was) I did not, however, have enough time to setup a comparable simulation to evaluate spoon designs. My trial expired about a week ago, and I see this aspect of the project as a lost opportunity. If Next Limit applied similar licensing practices as Maxon (verify it through .edu email address), they could offer an educational package of their RealFlow plugin.

Blender really came through for me. The learning curve was aggressive, but not impossible. While I found mantaflow to be a respectable and entirely capable fluid simulator, it was not without its own share of issues. I spent a lot of time making granular tweaks to improve the fidelity of my simulations, while also using the observations from my simulations to inform design decisions for my spoons in part 2 of this project.

Part 2: Design Iterations Based on User Testing

While this project required user testing and design iterations based on feedback, I decided to limit the user evaluations to address handle shape and the spoon’s overall dimensions. This was not an arbitrary decision or an excuse to focus on physical simulation of fluid dynamics (with user testing as an aside). No, this decision was based on the nature of the course from which it was assigned: Prototyping for Interaction Design. This semester I have have been focusing on designing for interaction (arguably, all designers do, at some point in their process, focus on this aspect). When thinking about the tools we use (to eat food) as a system, it is important to consider the touchpoints involved. The handle of a spoon is a non-trivial component. It can take on many forms, and naturally includes affordances. How someone holds a spoon, and how easy it is for them to use it are central to the evaluation of the design.

The iterations of design were highly generative in nature, inspired by both user evaluations and physical simulations, I maintained a homeomorphic continuity: treating the initial shape as an elastic form to be molded and reshaped to maximize performance. Knowing how a concave shape might be optimized to perform under rapid movement — I wanted to create something that would be useful, and the physical simulation of fluids facilitated a means of evaluation — is only one aspect of a more complicated interaction, and this test alone could not fully address human needs. When physical form is designed and directed to improve user interaction (and physical properties are given equal consideration), it is possible to create a truly useful tool. I realize that this is a very technical description, but it is easier to understand when properly visualized. I have rendered a compilation sequence to show how this spoon shape evolved to its final(?) form (I am still considering a physical prototyping stage for this project over the summer).

A sequence of fluid dynamics tests designed to evaluate fluid retention of concave forms. Carnegie Mellon University, School of Design, Prototyping for Interaction, Spring 2020.

Toward the latter half of this sequence, you will notice a change in colors (for both the liquids and spoons). I decided to differentiate the final rendering sequences as these were based on user evaluations. The colors chose for these final sequences are based on the color tags used for the user test:

These printouts are derived from DXF vector images exported from Fusion 360. The designs shown are oldest (top) to newest (bottom). The fifth design (blue) is rendered with a blue body and green liquid.

I printed and mailed the paper prototype to a potential user suffering from ongoing hand tremors (my partner’s mother). I sent this without written instructions. Instead, I only provided different color tags to facilitate feedback. My user let me know that the red spoon handle was in the “Goldilocks” zone in terms of size and shape: not too big, not too small, not too curvy, not too straight. Using this feedback I constructed the sixth and final (?) form — see the first image of this post.

The user test included a direct side-by-side comparison with existing dinnerware.

Before developing these simplified paper prototypes, I also experimented with ways of making more three-dimensional forms that could be sent in the mail. While this novel approach showed some potential, I was concerned with how user error might complicate or (even worse) bias feedback. Still, these paper prototypes helped me to better understand and interpret the scale of my 3D models.

Final Thoughts

This project still feels somewhat incomplete. Perhaps this is because the generative design process itself can always demand further iteration, or maybe it is because I have not yet created a physical prototype that can actually be tested as an eating instrument. Maybe it is only because there were still a few “rogue droplets” (grrrrrr) that I simply could not keep contained with the completion of my sixth iteration. Whatever the net effect might be from these various shortcomings, I am pleased with the learning opportunities that were presented throughout this exploration of design.

Were I to continue with this process, the next steps would be to 3D print the latest shape using a food-safe material (there are a few third-party vendors that offer this service). I would then ship that latest design for further user evaluation. I believe that there are still many additional iterations necessary before I could defend having created something that satisfies the criteria I set out with this project (i.e., a spoon that overcomes the challenges of involuntary muscle movements and essential tremors).

If I were to collaborate with others, I would also want to evaluate the ecological and economic impact of such a device. How might we go about manufacturing to appropriate scale? How might additional user tests with a wider audience influence the existing form? There remains many unanswered questions and a newfound respect for the power of generative design.

Bugs in the Blender

I have continued to have luck exploring the Fluid simulations in Blender, but this process has not been without its quirks. I recently encountered a strange issue related to Particle Radius settings

Particle Radius

The radius of one liquid particle in grid cells units. This value describes how much area is covered by a particle and thus determines how much area around it can be considered as liquid. A greater radius will let particles cover more area. This will result in more grids cell being tagged as liquid instead of just being empty.

Whenever the simulation appears to leak or gain volume in an undesired, non physically accurate way it is a good idea to adjust this value. That is, when liquid seems to disappear this value needs to be increased. The inverse applies when too much liquid is being produced.

What does this look like in practice? My most recent simulation actually seems to produce fluid as the scene progresses.

Nevertheless, I was able to gain critical insights into this form and will continue to iterate new designs. This is being done in conjunction with paper prototyping. These forms are less sophisticated, but still provide valuable information about how users will experience and interact with this flatware.

A Robot Took Your Job

Last week I returned from my trip to Memphis (thanks, Andy! Hope Meara’s potty training is going well!) and I’ve been playing catchup ever since. I’m getting back into Fusion 360 with some more challenging projects. This week we covered how to use joints in assemblies. This is pretty wild stuff. You can download models from GrabCAD.com and upload them Fusion 360. It auto-magically converts models to work natively (with mixed results) in the work space. From there, you can define joints and move parts in real time! We did this in class using an industrial robot model. Of course, this meant the robots needed to fight…

Four robots go in, four robots come out. Because they are metal, and very strong, and even knives won’t kill them!!

This wasn’t the actual assignment. Instead we needed to create a render scene involving an earlier model from this class being assembled by robots. I was grinding away at this all day yesterday, and finally got around to rendering it. Because of the complexity of the scene, it’s taking quite some time to bake in all of those rays at HD+ resolution. Here’s the object being assembled for reference:

This is based on an existing design from a vinyl shelf I bought to keep my Laserdisc collection in prime display condition. I fantasized about having an actual product made for Laserdisc, and what that might look like. You gotta with red trim right? Because LASERS!!

Here’s a technical drawing, if you want to build your own. This will probably hold about 250 titles, based on my experience with my current shelf ( tweaked the dimensions to give it a bit more depth and room to breathe between stacks.

i’ve been taking this class as an opportunity to not only learn the software, but also to push the limits of what the software can do. For me, this practice is like cartography. I’m mapping the borders by extending to the edge in all things. With this project, I wanted to not only torture test the rendering pipeline, but also test the limits of my beefy Hackintosh. As noted previously, my CPU appears to be the main bottleneck. But I wanted to see what it takes to exceed memory requirements. For this design and ray tracing session I’m utilizing ~25 GB of memory, and cooking my poor little quad-core Haswell® chip.

Nothing cooks like CAD! Note that the temperatures reflect a system with AIO liquid cooled CPU, and nine total fans, packed into an old PowerMac G4 case. Even when protein folding on both GPU and CPU, the system usually has a CPU core temperature ceiling of about 70˚ C.

It’s been over four hours as of writing this, and the rendering has not yet reached “final” quality. Scene complexity is a huge factor in rendering time.

MacOS Mojave (MacOS 10.14) is out!

Apple has released an update for MacOS, and it’s now available in the App Store. I’ll be holding off on this update for now. I’m already on iOS12 for my mobile devices, but until nVidia releases new Pascal drivers for my Hackintosh, I’m outta luck! Additionally, I prefer to wait until at least x.3 before updating my operating system. I’m currently rocking High Sierra 10.13.6, so I’m not that far behind.

ADOBE ILLUSTRATOR READING RESPONSE – ART 119

Over the weekend I had a chance to sit down and read over the first two chapters of Adobe Illustrator guide. I think I may have just confused myself. One of the key challenges is the fact that I have very little experience with Adobe’s Creative Suite. It’s like a whole new language. Furthermore, I do not have this software at home, and thus cannot easily relate to these new sets of terms. It is hard to apply knowledge when everything about it is purely theoretical. Last but not least: this was just a ton of new information.

At least there were pictures.

Clear as mud, but at least you can see it. Page 33 (Artboard printing)

llustrator is a massive heap of skeuomorphisms, and this only makes sense for those who began their careers in print making prior to the advent of computers in Graphics Design. This can be a huge challenge for newcomers, but this challenge is hardly unique to Illustrator. True story: a seventeen-year-old in one of my freshmen courses once described the save button in MS Word as a “purple truck”.

Beep! Beep! I’m a truck!

See, the thing was, she’d never even seen a floppy disk before. This graphic held no contextual meaning for her. She never experienced the joy of inserting a 3.5-inch piece of plastic into a clunky (yet essential) device to save her document. By the time she was old enough for K-12, the iMac was standard, and those computers (controversially) never shipped with a floppy drive.

“No floppy, no problem! You’ve got the World-Wide Web, son!” source:betanews.com

she accepted the function (saving her document was important, after all), but couldn’t make the connection between function and form. I’m not telling this story because it is funny (I still laugh when I think about her), but because I can now relate to her better after reading about Adobe Illustrator’s Tool Bar and Control Panel. Some of the symbols are easy to recognize, despite the fact that I’ve never actually used them in real life:

Page 3 – The tearoff toolbar

I’ve never used a fountain pen. I’ve had a classmate spatter ink on me accidentally with one, but that’s really about it. Generally speaking, I “get” pens. I’m fond of needlepoint over ballpoint, but that’s not the graphic here. What if I’d never seen a fountain pen before? How’d I ever hope to recognize the function?

I’m sure I’ll catch up, and with enough practice become proficient with this tool set. I just wonder how many “purple truck” moments I’ll have along the way.