Spatial Design | Textile Art | Immersive Interactive Storytelling ITP-Blog About
Hot Dance
Inspiration:
I wanted to create a gantry-based machine capable of fabricating custom inflatable Mylar shapes. ​
While experimenting for my Soft Robots class, I explored the process of creating inflatable Mylar forms, which involves two distinct steps: sealing the layers of Mylar and cutting the final shape. ​​​​​​​​​​​​​​
May 4, 2018
XYZ - ROBOTS
Assignment:
Develop a final project by reutilizing an existing gantry machine, reframing its X and Y functions, and reinventing the Z axis. The project focuses on both concept (why) and fabrication (how).
Machine Hacking | Soft Robotics | Digital Fabrication
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A Choreography of Heat and Motion
Hot Dance explores heat in motion through a synchronized choreography of two modified gantry machines. By reframing industrial precision as performative movement, the project transforms sealing and cutting into a mechanical dance where heat becomes both tool and expressive medium.
The AxiDraw is a versatile, precise plotter capable of drawing or writing on virtually any flat surface. Controlled through Inkscape, it allows complete design flexibility. Its unique design, with a writing head that extends beyond the machine body, makes it possible to work on surfaces larger than the plotter itself.
System Selection
I evaluated two gantry systems used in class—the X-Carve and the AxiDraw—considering their precision, motion range, and adaptability for Mylar sealing and cutting. Given its simplicity, accessibility, and high precision, I ultimately chose the AxiDraw as the foundation for the project.
While I had success in creating a few inflatable shapes, the technical challenges of fabrication inspired me to explore a mechanized solution that would allow for controlled heat application in motion, ensuring repeatable precision.
Laser cutting was precise and reliable for cutting materials, but sealing was done manually with an ironing tip. This method proved to be inconsistent, time-consuming, and challenging to produce in large quantities.
​​Approach
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Hacking the Z Axis. ​The AxiDraw was designed for writing instruments, with a limited Z-axis clearance of approximately 17 mm between the pen holder and the working surface. To adapt the system for an ironing tip, I needed to increase this vertical space while also ensuring the machine remained stable and precisely aligned.
Sealing and cutting. Because inflatable fabrication requires two actions—sealing and cutting—I decided to experiment with using two AxiDraw machines simultaneously: one dedicated to sealing the Mylar layers and the other to cutting the final form. The key challenge was positioning both machines so that the material remained stationary between these processes.
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This approach required engineering a raised, rigid base that would:
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Increase the effective Z height
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Secure the machines in place
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Maintain precise alignment between the two AxiDraws
Fabrication Process
I began by mapping the AxiDraw’s architecture, calculating its maximum usable movement area, and determining exact attachment points. Based on these measurements, I designed a support structure using a 1/4-inch acrylic sheet as the mounting base for the machines. The acrylic was laser-cut to include precise screw holes aligned with the AxiDraw’s metal base plates.
For the foundation, I used a plywood base etched with alignment guides. Three-inch wooden cubes were attached at each corner to elevate the acrylic platform and increase Z-axis clearance. The two AxiDraws were then mounted onto the acrylic and secured to the wooden supports using screws, following the etched guidelines to ensure precise positioning.
I replaced the original pen holder with a tube clamp capable of holding an ironing tip. A glass plate was placed at the center of the work area to control heat transfer and provide a stable sealing surface. Finally, I studied the movement speed, applied force, and heat levels required to consistently fuse the Mylar layers using the modified AxiDraw system.
Hot Dance transforms the machines’ movements into a dynamic, precise, heat-driven choreography, producing inflatable forms that combine technical precision and performative expression.
Outcome & Future Development
This hacked gantry system successfully reframed the AxiDraw’s original function, transforming it into a reliable tool for fabricating inflatable structures. As future development, I plan to further refine heat control and Z-axis calibration, and to produce a series of custom inflatable Mylar designs for my Soft Robots final project.
Outcome & Future Development
This hacked gantry system successfully reframed the AxiDraw’s original function, transforming it into a reliable tool for fabricating inflatable structures. As future development, I plan to further refine heat control and Z-axis calibration, and to produce a series of custom inflatable Mylar designs for my Soft Robots final project.
The project explores the expressive potential of heat-based fabrication, integrating motion and thermal energy into a mechanical choreography.