May 4, 2018
XYZ - ROBOTS
Hot Dance
Repurposed Robotic Gantry | Machine Choreography | 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 a tool and an expressive medium.
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).
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. ​​​​​​​​​​​​​​
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.
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.
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.
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.
​​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 sturdy support structure that can securely hold the two AxiDraws.
For the base, I used a plywood base etched with the alignment guides and attached three-inch wooden cubes in each corner to increase the Z-axis clearance.
Over this elevated platform, I placed 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.
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.
Hacking the Machine
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.
Ultimately, I analyzed the movement, speed, applied force, and heat levels required to consistently fuse the Mylar layers using the modified AxiDraw system, exploring the expressive potential of heat-based fabrication by integrating motion and thermal energy into a mechanical choreography.
Hot Dance transforms the machines’ movements into a dynamic, precise, heat-driven choreography, producing inflatable forms that combine technical precision and performative expression.
Sealing
Cutting
Final Piece
Outcome & Future Development
The modified gantry system successfully redefined the AxiDraw's original function, transforming it into a reliable tool for fabricating custom inflatable structures.
Future development will focus on refining heat control and Z-axis calibration while expanding the system to produce a broader range of inflatable forms.
From Hot Dance to Inflatable Connections
The repurposed robotic gantry developed in Hot Dance provides a reliable fabrication process for the custom pneumatic modules used in Inflatable Connections, the final project for the Soft Robotics course.