Aluna Everitt A Novel Approach to Interface Fabrication Using Laser Cut Optically Clear Perspex B.Sc. (Hons) Information Technology for Creative Industries 20/03/2015 Aluna Everitt SCC.300 2015 “I certify that the material contained in this dissertation is my own work and does not contain unreferenced or unacknowledged material. I also warrant that the above statement applies to the implementation of the project and all associated documentation. Regarding the electronically submitted version of this submitted work, I consent to this being stored electronically and copied for assessment purposes, including the Department’s use of plagiarism detection systems in order to check the integrity of assessed work. I agree to my dissertation being placed in the public domain, with my name explicitly included as the author of the work.” Date: Signed: Page 1 of 68 Aluna Everitt SCC.300 2015 ABSTRACT Increasingly digital fabrication technologies are being adopted in a wide range of settings as they allow users to rapidly and accurately produce physical designs. Of these technologies, laser cutters are particularly interesting as they are able to work with a wide range of materials. This report explores the ways in which the optical properties of clear Perspex material can be exploited in order to add interactive and visual display capabilities to static objects. This has potential to support the creation of a new range of wearable technologies, enclosures, and other designs that do not require expensive and generic circuitry and electronics. To achieve this, an exploration of material properties was conducted to devise novel approaches of producing interactive visual displays using a laser cutter. From this, three fundamental interface elements are produced (i.e. a button, an accelerometer, and a seven-segment display) and combined into a wearable watch prototype. Finally, a discussion of design guidelines is presented. Page 2 of 68 Aluna Everitt SCC.300 2015 TABLE OF CONTENTS 1. Introduction .......................................................................................................................... 8 1.1 Research Question ............................................................................................................ 8 1.2 Exploring Design Space ................................................................................................... 8 1.3 Outline of Report .............................................................................................................. 9 2. Background ........................................................................................................................ 10 2.1 Related Work.................................................................................................................. 10 2.2 Summary ........................................................................................................................ 13 3. Material Exploration ......................................................................................................... 14 3.1 Visual Exploration.......................................................................................................... 14 3.1.1 Distance Study ......................................................................................................... 14 3.1.2 Angle Study ............................................................................................................. 16 3.2 Interactive Exploration ................................................................................................... 19 3.2.1 Touch Study 1.......................................................................................................... 19 3.2.2 Touch Study 2.......................................................................................................... 22 3.2.3 Touch Study 3.......................................................................................................... 24 3.3 Discussion and Summary ............................................................................................... 25 4. Prototype Elements ............................................................................................................ 26 4.1 Interactive Application Elements ................................................................................... 26 4.1.1 Button ...................................................................................................................... 26 4.1.2 Accelerometer .......................................................................................................... 28 4.2 Interface Application Elements ...................................................................................... 31 4.2.1 Initial Seven-Segment Display (LEDs Around 4 Sides) ......................................... 31 4.2.2 Initial Lighting Observations ................................................................................... 32 4.2.3 Refined Seven-Segment Display (LEDs on Bottom) .............................................. 35 4.3 Discussion and Summary ............................................................................................... 36 5. Application - Watch Prototype ......................................................................................... 38 5.1 LED Enclosure ............................................................................................................... 38 5.2 Interface .......................................................................................................................... 39 5.3 Interactive Button ........................................................................................................... 43 5.4 Final Integration ............................................................................................................. 44 5.5 Discussion and Summary ............................................................................................... 45 Page 3 of 68 Aluna Everitt SCC.300 2015 6. Design Considerations and Discussion ............................................................................. 47 6.1 Apparatus ....................................................................................................................... 47 6.2 Design and Fabrication of Enclosure ............................................................................. 47 6.3 Design and Fabrication of Display ................................................................................. 48 6.4 Programme Display ........................................................................................................ 49 6.5 Programme Interactive Element ..................................................................................... 50 6.6 Discussion and Summary ............................................................................................... 50 7. Conclusion .......................................................................................................................... 52 7.1 Review of Aims .............................................................................................................. 52 7.2 Limitations ..................................................................................................................... 52 7.3 Future work .................................................................................................................... 53 7.4 Learning Outcomes ........................................................................................................ 53 Bibliography ........................................................................................................................... 54 Appendices .............................................................................................................................. 55 Prototype Elements .............................................................................................................. 55 Seven-Segment Display Chapter .......................................................................................... 56 Watch Chapter ...................................................................................................................... 59 Project Proposal.................................................................................................................... 60 Working Documents Link: http://www.lancaster.ac.uk/ug/everitta Report Word Count: 13,648 Page 4 of 68 Aluna Everitt SCC.300 2015 TABLE OF FIGURES Figure 2.1: Device fabricated through Printed Optics [left]. Device with curved display produced through PAPILLON [right]………………………………………..………………10 Figure 2.2: 3D printed device fabricated through Savage’s algorithmic process of subtraction to accommodate manually embedded active components………………………...…………11 Figure 2.3: Ficon tangible 3D display devices with interactive touch capabilities through table top systems……………………………………………………………………………..12 Figure 3.1: The hardware used in the LDR distance experiment. Black plastic used on LDR so no light reflects…………………………………………………………………………....15 Figure 3.2: This graph shows the strong negative correlation between the means of the two variables: light intensity and material length…………………………………………..…….16 Figure 3.3: Arduino, LED and LRD circuit mount for angle study…………………………17 Figure 3.4: This line graph shows the means of expected light intensity readings (based on the distance formula) and actual light intensity readings for every 10° variation in the material…………………………………………………………………………………….....18 Figure 3.5: The edges and corner of the material are illuminated brighter than the surface…………………………………………………………………………………..……18 Figure 3.6: Imperfections can be seen on the laser cut edge of the material - under 30 x magnifications………………………………………………………………………………..18 Figure 3.7: Arduino, LED and LRD circuit mount for touch study. Finger is applied at 20mm where the LDR is positioned. Then touch is applied every 20mm along the surface until 120mm distance is reached. No touch is applied at 0mm distance…………….…………….20 Figure 3.8: This line graph shows the average light intensity from the bottom of the material when touch is applied. Touch distance 0mm represents that no touch is applied and touch distance 20mm represents when touch is applied directly above the LDR sensor……...……20 Figure 3.9: Volume control device concept using a strip of clear material, an LED light source, and an LDR sensor……………………………………………………………….…..21 Figure 3.10: Arduino, LED and LRD circuit mount for touch study 2…………………...…22 Figure 3.11: Average light intensity from the first data sample collected. This shows an irregular pattern that was not expected………………………………………………….……23 Figure 3.12: Line graph visualising the average light intensity from the second data sample collected. This shows even more irregularity that was not expected…………………….…..23 Figure 3.13: Light intensity decreases as the number of fingers on the surface of the material increases………………………………………………………………………………...……24 Figure 4.1: Button light switch when no interaction occurs…………………………...……27 Page 5 of 68 Aluna Everitt SCC.300 2015 Figure 4.2: As pressure on the surface of the material increase LED 2 changes colour from yellow to pink…………………………………………………………………………….…..28 Figure 4.3: Accelerometer prototype (top not present) with LED and LDR situated opposite sides of rectangular enclosure………………………………………………………30 Figure 4.4: Comparison of vertical and horizontal displacement based on light intensity….30 Figure 4.5: SSD enclosure (85x120mm) consisting of three layers with LEDs positioned on all four sides………………………………………………………………………………….31 Figure 4.6: Test 1 with five active LEDs illuminates all of the seven segments and visualises light path from LED sources proficiently on matt etches…………………………………....32 Figure 4.7: Criss cross pattern etches distribute light rays more consistently compared to flat matt etches……………………………………………………………………………………33 Figure 4.8: Cuts from test 9 enhances illumination of five segments………………….……33 Figure 4.9: Design and applied SSD with black material insert that isolates each segment of the display...…………………………………………………………………………….……34 Figure 4.10: SSD displaying digits from 0 to 9 in a range of colours in full ambient light…………………………………………………………………………………………...34 Figure 4.11: Two layer SSD with LEDs only at the bottom of the enclosure……………….35 Figure 4.12: Single layer SSD design with black inserts and final implementation of an SSD displaying the figure “4”……………………………………………………………………..36 Figure 4.13: Printed Optics numeric display (a) consisting of embedded air pockets that reflect light when illuminated (b). The numeric display fabricated through laser cutting (c) in contrast only uses one layer of material to visualise figures 0-9……………………………..37 Figure 5.1: LED enclosure for watch prototype with chain of seven LEDs situated inside…………………………………………………………………………………………38 Figure 5.2: Refined display for interactive watch prototype. Consisting of optically clear Perspex (depth 5mm) and corresponding black material partitions (width: 0.72mm)………………………………………………………………………………...……39 Figure 5.3: Initial watch interface (secured with adhesive to ensure robustness) inserted into LED enclosure………………………………………………………………………………..40 Figure 5.4: Due to angle restrictions the initial design of the display did not allow light to be transmitted efficiently to the top sections as shown by numerals 6 and 9…………………...41 Figure 5.5: Refined design of the display enhanced illumination of both figures regardless of light or dark background and the addition of fascia………………………………………….42 Figure 5.6: Button actuation device consisting of one LED, one LDR, and a strip of optically clear material…………………………………………………………………………………43 Figure 5.7: Figures 0 to 9 displayed on final watch prototype in full ambient light. The middle section is no as well illuminated compared the surrounding sections………………..44 Page 6 of 68 Aluna Everitt SCC.300 2015 Figure 5.8: Figures 0 to 9 displayed with no ambient light present. Each figure is visualised with greater clarity though the middle segment is still less obvious…………………………44 Figure 5.9: Watch used when no ambient light is present compared to when ambient light is present……………………………………………………………………………………..…45 Figure 6.1: To display numeric figure “3” LEDs 3, 4, 5, 6, and 7 must be active whilst LEDs 1 and 2 must be inactive…………………………………………………………………..….49 Figure 6.2: Example Arduino processing code for visualising numeric figure “3”……..…..49 Figure 6.3: Word cloud of key phrases and words taken from observations conducting during open day demonstrations……………………………………………………………….…….51 Figure 7.1: Voronoi diagram isolating each of the eight points with maximum space around each centre……………………………………………………………………………………53 Page 7 of 68 Aluna Everitt SCC.300 2015 1. INTRODUCTION 1.1 RESEARCH QUESTION The majority of interactive interfaces use electronic components situated underneath the surface of a display (Lin [8], Orchard [11]). Alternatively, interfaces are visualised with outside projection systems that emit light on top of surfaces (Blöchl [4], Suman [14]). These methods however are often highly complex and use expensive electronics that are purchased as separate units. These limitations infringe development and fabrication of interactive interface devices. Alternative processes, such as 3D printed optical displays, are in development for simplifying and enhancing the design and fabrication of informative visual displays. However 3D printed optic displays are often highly complex to implement with great cost on materials, equipment, and lead time. By extending findings from previous research in the field of interface fabrication, simple interfaces with limited active components and low cost materials and fabrication tools can be utilised for a range of applications. 1.2 EXPLORING DESIGN SPACE The aim of this project is to design and develop an alternative process of developing interfaces with interactive capabilities. This process will require a minimum number of electronic components situated on a single side of a Perspex-based display. Using a single optically clear Perspex sheet for fabrication of displays further simplifies the application process. This enables new varieties of low cost user interfaces (UI) to be developed. Transparent display integrated with ubiquitous computing could enable new forms of wearable technology in future work. Eliminating the need for highly technical electronics and greater knowledge of electrical implements interfaces could be custom fabricated for a wider range of users. Developing simplistic processes of fabricating UIs could reduce both cost and lead time and allow further innovation of wearable and ubiquitous technology. With the use of laser cutting techniques interactive devices could be fabricated with greater ease compared to other techniques such as 3D printing. Laser cutters are now more accessible and cheaper compared to optical 3D printers and use more efficient and simplistic application methods. Optically clear Perspex material is also much cheaper and highly durable compared to liquid photopolymer material often used for optical 3D printing. The use of laser cut Perspex could also reduce the number of active complements needed and decreasing manual assembly. Three basic varieties of active components could be used to ensure simplistic implementation. Multicolour light-emitting diodes (RGB LEDs) would provide visualisation and enable interactivity in conjunction with other components. User interaction would be enabled through light transmission variations within the material, recorded by a lightdependent resistor (LDR) sensor. For simplistic computations an Arduino processing board could be used to control any LEDs used to visualise meaningful information based on light intensity variance. Construction using Perspex material enables low cost yet highly durability devices to be produced. In addition, a novel process of developing interactive interfaces enables highly customisable devices to be tailored to an individual’s needs and specifications. Using a 2D vector based design programme, such as Illustrator, users would be able to manually draw outlines of a desired interface. The design space would integrate 2D vector Page 8 of 68 Aluna Everitt SCC.300 2015 environments for added simplicity. This process would require minimal technical knowledge needed compared to implementing 3D modelling for printing 3D devices. 1.3 OUTLINE OF REPORT Using laser cut Perspex material this project aims to demonstrate an enhanced process for the design and fabrication of novel interfaces with interactive capabilities. This project aims to present the following contributions: 1. A general approach for using laser cut Perspex prototype elements to display information and sense user input. 2. Techniques for visualising information using laser cut optically clear material, including use of etchings and cuts to enhance luminosity of displays. 3. Techniques for sensing user input with laser cut transparent material, a single light source, and a sensor. This includes touch pressure input with an embedded sensor and mechanical displacement of light wave guides. 4. Example application that demonstrates how laser cut optically clear material can be implemented to fabricate wearable transparent interactive displays. Firstly this report describes and evaluates current processes for rapid prototyping of interactive interface devices and how current contributions could influence this project. Secondly, this report explores properties of optically clear Perspex material and how these can be exploited for visualisation and interaction. Two studies were performed to analyse visualisation using optically clear Perspex plastic with length and angle as independent variables. Touch studies were then performed to explore interactive capabilities using light intensity as an input variable when pressure is applied to surface of the material. The derived findings were then applied to prototype elements which could be integrated into active devices that use both interaction and interface visualisation. This demonstrates a wide range of capabilities enabled by laser cut fabrication which utilises light properties of optically clear Perspex material. A smart watch prototype was then designed and fabricated based on principle findings from the exploration and evaluation of pervious individual interaction and visualisation prototype elements. The main process for designing and fabricating interface devices with input capabilities is then described and evaluated. Finally a conclusion details a summation of findings from the project overall, with limitations found, and future applications of the design and development process. Page 9 of 68 Aluna Everitt SCC.300 2015 2. BACKGROUND The problem statement is to find an efficient process for fabricating novel interfaces with interactive capabilities. It is proposed low cost rapid prototyping could be enabled by using laser cut optically clear Perspex material and embedding active components such as a Light Dependent Resistor (LDR) and Light-Emitting Diode (LED) for interaction and visualisation. Discussions of relevant systems, approaches and their implications to this project are found below. 2.1 RELATED WORK With recent development of optical quality 3D printers there is now an increase in construction of customisable interfaces with interactive capability. This introduces great potential for low cost and lead time device fabrication. Wills et al. [16] describe an approach to 3D printing customizable interactive devices categorised as Printed Optics. Functioning devices are designed within a digital 3D modelling editor and realized into a single physical form through optical 3D printing. Active components and optical quality elements are embedded into the device as part of the fabrication process. The design and construction of non-flat interactive interfaces is also becoming an emerging field of research as described by Rümelin et al. [12]. By exploring alternative display forms which navigate away from traditional flat displays for interactive applications Brockmeyer et al. [5] elevates the approach taken from Printed Optics to a new domain of interactive interfaces. The system PAPILLON enables the design of curved display surfaces for information visualisation and input capabilities through 3D modelling. The interactive device is then fabricated through 2D optical printing as a single object. Figure 2.1 shows a toy character with an embedded display visualising a heart shape developed through Printed Optics (left) and another character with embedded curved display fabricated through PAPILLON. Figure 2.1: Device fabricated through Printed Optics [left]. Device with curved display produced through PAPILLON [right]. The current cost of fabricating such devices however is great in both material cost and obtaining access to a 3D printer with optical printing capabilities. The majority of the devices developed are also limited on practical use. They can be categorised predominantly as single Page 10 of 68 Aluna Everitt SCC.300 2015 value devices, as described by Mader et al. [9]. Due to multiple materials used and high number of layers needed to produce just one device elevates lead time and cost of fabricating. Savage et al. [13] describe a similar approach to designing and developing interactive devices by embedding optical light tubes within interiors of 3D printed objects. Electronic sensors or actuation components are manually embedded into the interior of 3D printed objects. Subtractive processes are implemented through an algorithmic approach to generate space within 3D models for insertion of active components and electronics. Through manual insertion electronic sensors or actuation mechanisms are situated within 3D printed objects to enable interactivity as seen in Figure 2.2. Figure 2.2: 3D printed device fabricated through Savage’s algorithmic process of subtraction to accommodate manually embedded active components. Baudisch et al. [2] demonstrates a tangible system, Lumino, which visualise images when applied to diffuse illumination table surfaces, such as Microsoft Surface. Glass fiber bundle blocks are arranged into three-dimensional (3D) structures atop an illuminated surface to move visual focus to designated locations upon the table surface. Lumino enables custom optimisation of a tangible visual unpowered and maintenance free system. Takada et al. [15] presents a similar display system, Ficon, which uses properties of optical fiber to visualise information on table-top 3D displays. Light from the bottom of a light emitting surface is conducted up to the top of a tangible 3D display through optically clear fiber. This allows a user to control visual displays and their position using tangible objects as seen in Figure 2.3. The same principle of situating a light source at the bottom of the display will be applied to this project. However, light sources at the bottom of the device will visualise information on the outer front face of the display. Through enhanced understanding of material properties and limitations a fabrication process can be developed to efficiently and clearly enable informative visualisations using laser cut optically clear material. The refinement of this process will also ensure information could be viewed in full ambient light (sun light for example). Page 11 of 68 Aluna Everitt SCC.300 2015 Figure 2.3: Ficon tangible 3D display devices with interactive touch capabilities through table top systems. The fabrication processes for developing interactive interface devices discussed above are becoming more wide spread and have great potential to change the process of how interactive user interfaces are manufactured. However, there are limitations of using such design and implementation processes. Optical fibres or light pipes need to be connected to a sensors of some form to enable interactive capabilities. With the use of laser cut components there should no direct contact between the material and sensors. Individual material components should also be tangible and easily reconstructed for enhanced customisation without the need to fabricate new structures. As a result lead time and cost of material consumption could be reduced compared to 3D printing techniques. One of the main limitations of 3D printing is that there is need for structural support when fabricating devices with complex geometry. In some cases, device enclosures must be printed in several parts and manually assembled to avoid structural weakness. As a solution laser cutting could be applied to construct similar devices from robust material (Perspex sheets) when using a 2D vector design environment. Although manual assembly would be required, with careful design decisions the number of components needed would be reduced compared similar 3D printed devices. Mueller et al. [10] also describe a rapid prototyping system, LaserOrigami, that produces 3D objects significantly faster compared to traditional 3D printing techniques using specified laser cutter settings. By stretching and folding the material, rather than placing joints, the need for manual assembly could be eliminated. 3D printers also vary in quality of application. It is impractical to construct certain shapes using 3D printers that are less callable of structural support. As a result it becomes unfeasible to replication devices for open source libraries with complex geometry. Laser cutters are higher precision manufacturing machines where quality and robustness of fabricated objects often depends on the material used rather than the apparatus itself. The precision of laser cutters may vary slightly, but this is often due to quality of maintenance. The LaserPro Spirit GE, used for this project, is equipped with a sealed carbon-dioxide (CO2) laser that emits concentrated and invisible laser radiation with a wavelength of 10.6 microns in the infrared Page 12 of 68 Aluna Everitt SCC.300 2015 spectrum. As described by Bergman and Stockman [3] the laser is the acronym for Light Amplification by Stimulated Emission of Radiation. The CO2 laser electrically stimulates the molecules within a carbon dioxide gas mixture. When focused through a lens, this highlyintense, invisible beam will vaporize dense materials with high precision. Subject to speed and intensity of the projected beam, the CO2 laser will engrave or cut through Perspex materials of varied depths. 2.2 SUMMARY Rapidly prototyping interfaces with interactive capabilities using simplistic tools and fabrication techniques is becoming increasingly popular. However the majority of current contributions to this field involve complex implementation processes such as 3D modelling and electronic assembly. The cost of material and machinery used for fabrication using optical 3D printers for example is often high and inaccessible to general users. Lead time of production also increases for more complex implementations. Often devices fabricated using such approaches are defined as single-value and have little practical use. Laser cutters are more commonly found within design spaces and require cheaper material (Perspex) which easily accessible. Lead time is also decreased with laser cutters as often only one layer of material is needed to produce prototypes. This makes it easier to change elements of current devices without the need to recreate the whole device again. As a result cost of material and lead time is reduced. Before design space for fabricate interactive interface devices using a laser cut material can be explored there must be an understanding of material properties, limitations, and opportunities. Page 13 of 68 Aluna Everitt SCC.300 2015 3. MATERIAL EXPLORATION In order to understand how laser cut optically clear material can be implemented to fabricate interactive displays explorations of light properties must first be analysed. Exploring reflection, refraction, and diffusion fundamentals aids the design and development of prototype elements that unify to create a fully functioning interactive display. First, visual exploration studies extend current knowledge for visualising information using laser cut optically clear material. Secondly, interactive touch studies extend current knowledge for sensing user input with laser cut transparent material, a single light source, and a sensor. 3.1 VISUAL EXPLORATION Two exploratory trials were conducted to uncover the effects of Frustrated Total Internal Reflection (FTIR), as described by Han [6, 7], through laser cut clear Perspex material. The first study investigated the affects of light transmission through a range of material lengths. The second trial explored how angled cuts in the material affect light transmission. By understanding how light transmission varies depending on the two independent variables (length and angle) a model can be developed which predicts FTIR transmission through the material. These studies should aid designers who wish to create laser cut interactive interfaces themselves, and also provide understanding of how sensors and switches, similar to Wills et al. [16] Printed Optics, can be designed efficiently but using laser cut material instead. 3.1.1 DISTANCE STUDY To extend understanding how optical light properties of clear Perspex are affected depending on scale, a distance study was performed. How is light transmission affected with increased distance of straight laser cut optically clear material? Light intensity measured by a light-dependent resistor (LDR) decreases as material length increases. LDR readings of light transmitted through different lengths of optically clear Perspex material are recorded. Lengths range from 10mm up to 200mm, at 10mm intervals (20 samples total). Each sample consists of a 5 second read transmitted every 10 milliseconds from the Arduino (500 samples total). This time was chosen to analyse variation in the light intensity over a prolonged period of time to ensure anomalies are minimised. An Arduino UNO was connected to a NeoPixel light-emitting diode (LED) and an LDR. The LDR was connected using a 10k resistor. All of these were mounted onto a wooden board to secure everything in place and enable portability. A serial command was used to trigger the experiment – input: material length (mm). The Arduino outputted a Comma Separate Values Page 14 of 68 Aluna Everitt SCC.300 2015 (CSV) data set to make it easier for R and Excel to process and output graphs. See Figure 3.1 for an image of the hardware implementation. Note how the Perspex material is held in position using a hole in both the LED and LDR cases. This also ensures secure contact and less escaped light between the material, LED, and LDR sensor. LED light source LDR sensor Clear Perspex Material (5mm x 3mm) Figure 3.1: The hardware used in the LDR distance experiment. Black plastic used on LDR so no light reflects. A distance and light intensity correlation coefficient was computed to assess the relationship between light intensity and the Perspex material length. A scatterplot summarises the results (Figure 3.2). There was a strong negative correlation between the two variables (r = -0.96, n = 18, p = < 0.001) that indicates light intensity decreased slightly as distance increases. This decrease is linear which means it can be modelled easily using the data captured: This experiment was limited to samples ranging up to 200mm; further experiments are needed to test if the model can be used on much longer lengths of Perspex material (e.g. 1000mm). This formula can be written into an Arduino program to estimate the light intensity drop when creating prototypes with different material lengths such as, a bracelet. The next step in the research is to perform a similar experiment but with different angles. Page 15 of 68 Aluna Everitt SCC.300 2015 Figure 3.2: This graph shows the strong negative correlation between the means of the two variables: light intensity and material length. 3.1.2 ANGLE STUDY To enhance the scope of fabricating interface using laser cut material, light properties of transparent Perspex with a range of angle cuts was explored. What are the effects on light transmission with angle of optically clear material variance? Light intensity decreases as the angle of the material increases. Acute angles will allow more light transmission whereas obtuse angles will transmit less light. Record LDR readings for light transmitted through clear Perspex material, where each piece of material has a different angle. These angles will range from 10° degrees up to 170° degrees, at 10° degrees intervals (17 samples total). Each sample consists of the same 5 second read transmitted every 10 milliseconds from the Arduino (500 sample total). Each material has a 3 mm inner corner radius and a length that allowed fit into the cases as appropriate. The distance model was used to approximate the expected LDR reading for each length of material. Page 16 of 68 Aluna Everitt SCC.300 2015 The hardware implementation was very similar to that of the distance experiment (Figure 3.3). The LED cases could be removed from the Arduino mount to accommodate the tighter angles of material. The serial command that was used to trigger the experiment used two input independent variables: angle of material (degrees) and material length (mm). LED light source LDR sensor Clear Perspex Material (5mm x 3mm) at 50° angle Figure 3.3: Arduino, LED and LRD circuit mount for angle study. A line graph (Figure 3.4) shows both the expected LDR readings (based on material length formula derived from the distance study) and the actual LDR readings from the angle experiment. The difference between these lines represents the impact of the angle on the LDR intensity. From this it can be observed that smaller angles have less impact than larger angles. The difference is more significant for obtuse angles over 130°. Page 17 of 68 Aluna Everitt SCC.300 2015 Figure 3.4: This line graph shows the means of expected light intensity readings (based on the distance formula) and actual light intensity readings for every 10° variation in the material. Two correlation coefficients were computed to assess the relationships between (a) length and light intensity (r =-0.92, n=15, p=<0.001) and (b) the angle and light intensity (r =-0.65, n=15, p=<0.005). From the statistics it is evident that there is stronger negative correlation in the relationship between length and light intensity compared to that of angle and light intensity. This means that considering length has more impact in light transmission compared to considering angle. From the observations taken during the experiment it was clear that more light was escaping through the laser cut edges and corner angle of the material than the polished surface, as shown in Figure 3.5. This is most likely due to laser induced damage where the material is cut. These imperfections can be seen in the microscopic image in Figure 3.6. Figure 3.6: Imperfections can be seen on the laser cut edge of the material - under 30 x magnifications. Figure 3.5: The edges and corner of the material are illuminated brighter than the surface. Page 18 of 68 Aluna Everitt SCC.300 2015 3.2 INTERACTIVE EXPLORATION Three touch studies were conducted to evaluate interactive properties of optically clear Perspex when light is directed throughout its core. A range of finger based input variables were tested taking into consideration the phenomena of Frustrated Total Internal Reflection (FTIR). Based on the findings from these touch studies a larger design space could be explored for implementing interactive prototype elements. 3.2.1 TOUCH STUDY 1 To enable interactive capabilities of laser cut interfaces, this study demonstrates how transparent Perspex can be used to detect touch. Can finger position on the surface of laser cut optically clear material be detected depending on light intensity changes? When touch on the surface of the material is closer to the LDR the variation in light intensity is greater. Take LDR reading of light transmission when a finger (15mm width) is applied to specific points on the surface of the material. Material length used 130mm. Touch will be applied every 20mm along the surface of the material. Underneath the longer horizontal piece there will be a shorter piece of material that is 20mm in height. This shorter piece of material will be placed 20mm away from the end of the material and will also be connected to an LDR sensor. Using FTIR the light will travel down through the shorter piece of material when touch is applied to the surface of the material. The first recording will be at 0mm where no touch is applied at all to the surface of the material. Then light intensity will be recorded when the finger is applied 20mm away from that LDR position (40mm on length of material surface), this is repeater every 20mm until finger touch is applied at 120mm on the surface material. The hardware implementation was very similar to that of the distance and angle experiments. However the LDR sensor was placed at the bottom of the smaller vertical piece of material to take reading of light transmission (see Figure 3.7). The serial command that was used to trigger the experiment used two input independent variables: horizontal material length (mm) and touch distance away from the original LDR position 20mm away from the end of the surface material. Page 19 of 68 Aluna Everitt SCC.300 2015 Clear Perspex Material (5x3x130mm) LDR sensor Material length 20mm LED light source Figure 3.7: Arduino, LED and LRD circuit mount for touch study. Finger is applied at 20mm where the LDR is positioned. Then touch is applied every 20mm along the surface until 120mm distance is reached. No touch is applied at 0mm distance. Figure 3.8 illustrates the average light intensity passing though the material when touch is applied. Touch distance 0mm represents the reading when no touch is applied. Touch distance 20mm represents when the finger is directly below the LDR sensor. This is when the greatest light intensity change occurs as the finger is applied directly above the LDR. It peaks dramatically compared to all of the other readings and this is due to the light rays reflecting from the finger down towards the LDR instead of passing horizontally though material. Figure 3.8: This line graph shows the average light intensity from the bottom of the material when touch is applied. Touch distance 0mm represents that no touch is applied and touch distance 20mm represents when touch is applied directly above the LDR sensor. Page 20 of 68 Aluna Everitt SCC.300 2015 Considering that 0mm touch distance represents no touch applied it is evident that there is a slight decrease in light intensity when the finger is applied further along the surface of the material, after the initial 20mm mark. This means that some of the light reflecting downwards into the LDR is lost/absorbed when single finger touch occurs away from the LDR. From these results two observations can be made: 1. When finger touch is applied directly above the LDR sensor more light rays travel down through the shorter vertical Perspex material that is connected to the LDR sensor, this FTIR phenomenon increase the light intensity LDR reading. 2. When comparing no touch with touch further away from the LDR there is a slight decrease in light intensity. This could be due to the light rays being disturbed earlier when reflecting through the material and thus more rays escape before reaching the LDR. From the results found during the touch study it was found that interactivity can be achieved using light intensity as a variable input. A simplistic button action can be developed where the user could activate a command by applying pressure touch to a particular part of the material surface where the LDR is located. This interactivity is achieved though FTIR variations. Light transmission changes can also occur when touch is applied at further distances away from the LDR a simple two state variable interactive interface can be developed. A simple control system (see Figure 3.9) could be created, where light transmission increase is detected using the LDR and the volume of speakers can also increase. When relatively low light intensity decrease is recorded then the volume is turned down. Human finger Clear material LED light source LDR underneath clear material Speaker volume increases when LDR reading is high and decreases when LDR reading is low Figure 3.9: Volume control device concept using a strip of clear material, an LED light source, and an LDR sensor. Page 21 of 68 Aluna Everitt SCC.300 2015 3.2.2 TOUCH STUDY 2 To enhance the range of user input capabilities, a study explores possible correlation between position of a finger and the resulting light intensity. Can finger touch position be detected depending on light intensity changes when an LDR is placed directly opposite an LED? When touch is applied on the surface of the material close to the LDR the variation in light intensity is greater. The LDR reading of light transmission will be taken when a finger (15mm width) is applied to specific points on the surface of the material. Material length used 130mm. Touch will be applied every 10mm along the surface of the material. The LDR sensor will be located directly opposite the LED light source and connected to the material (5 x 3 x 130mm in dimensions). Using FTIR the light will travel through the material and when touch is applied to the surface light rays reflecting within the material will be disrupted and more light should escape through the material before reaching the LDR sensor. The first recording where touch is applied will be at 10mm away from the LDR. This is repeated at intervals of 10mm until the touch applied is 120mm away from the LDR (12 samples total). The hardware implementation was very similar to that of the distance and angle experiments where the LDR sensor was placed directly opposite the LED on the other end of the material as seen in Figure 3.10. The serial command that was used to trigger the experiment used two input independent variables: horizontal material length (mm) and touch distance away from the LDR starting at 10mm on the material surface. LDR sensor Clear Perspex Material (5x3x130mm) LED light source Figure 3.10: Arduino, LED and LRD circuit mount for touch study 2. Page 22 of 68 Aluna Everitt SCC.300 2015 Figure 3.11 shows a decrease in light intensity up until touch is applied 50mm away from the LDR on the surface of the material. Then there is a high increase in light transmission in when touch is applied between 60mm and 70mm, followed by another decrease at 80mm distance. This result was unexpected and another sample of data was collected when repeating the experiment to ensure these results were valid. Figure 3.11: Average light intensity from the first data sample collected. This shows an irregular pattern that was not expected. Figure 3.12 shows the second data sample has even greater disparity. Overall the data has high variance between samples and there is no consistent relationship found between the touching distance ad light intensity when one finger is applied on a particular point on the surface of the material when the LDR is positioned directly opposite the LED light source. Figure 3.12: Line graph visualising the average light intensity from the second data sample collected. This shows even more irregularity that was not expected. Page 23 of 68 Aluna Everitt SCC.300 2015 3.2.3 TOUCH STUDY 3 This study explores if laser cut material could enable multi-touch interaction based on light intensity changes corresponding to number of fingers applied to the surface. Does applying pressure with multiple fingers effect light intensity when the LDR is placed directly opposite the LED? When touch is applied with more than one finger on the surface of the material light intensity decreases. Take LDR reading of light transmission when a finger (15mm width) is applied on the surface of the material. Material length used 130mm. Record light intensity when additional fingers are touching the surface one at a time until 10 samples are collected. The hardware implementation was very similar to that of “touch study 2” experiment where the LDR sensor was placed directly opposite the LED on the other end of the material as seen in Figure 3.10. Multiple fingers were applied to the surface of the material and light intensity was recorded for sets of fingers in close proximity. Starting from 1 finger and incrementing until 10 fingers were applied to the surface of the material. The serial command that was used to trigger the experiment used two input independent variables: horizontal material length (mm) and number of fingers applied on the material surface. As the number of fingers on the surface of material increase, light intensity within the material decreases (see Figure 3.13). The application of a large number of fingers on the surface of the material can be used as a form of user input. Figure 3.13: Light intensity decreases as the number of fingers on the surface of the material increases. Page 24 of 68 Aluna Everitt SCC.300 2015 3.3 DISCUSSION AND SUMMARY This chapter considers visual and interactive explorations of optically clear material to enable efficient fabrication techniques for prototyping interactive interfaces. In terms of visual capabilities, a linear model of light transmission was derived through various lengths of material. This showed that light intensity through the material was constant, even with ambient light present, yet varied with material length. In terms of interactivity, touch could be detected using an LDR to read any changes of light intensity exploiting FTIR variance. To apply scope to the explorations some parameters were not explored such as width of material impact on light intensity. Those selected for exploration had greater impact on devices fabricated for this project. To increase validation of studies performed large sample sizes (n=500) were used to minimise anomalies. Independent variables were sampled in fixed steps such as length (between 10mm to 200mm, every 10mm) and angle (between 10° to 170°, every 10°) as it would be impractical to laser cut every possible angle. Although observations have not been obtained beyond these ranges, additional findings are expected to follow the same model. In terms of interaction, only finger based interaction was explored. This limits the exploration of alternative input possibilities such as use of stylus pens. However given prevalence of touch based interaction this method is justified. In future studies an extended range of material lengths and widths should be tested to gain enhanced understanding of impact on larger scale implementations. In addition, alternative methods of input interaction should also be explored to further explore possibilities of expanding the design space for prototyping interactive displays. In conclusion the work in this chapter enables the design and fabrication of interface prototypes such as switches, sliders, and touch detection. These can be a range of sizes and shapes as explored through the studies. In the next chapter this is built on by creating fundamental prototype elements such as switches and displays. This enables the construction of a prototype that combines all of these elements. Page 25 of 68 Aluna Everitt SCC.300 2015 4. PROTOTYPE ELEMENTS This chapter details meaningful uses of properties found from the previous light explorations. Single systems for interaction and information visualisation are implemented for a range of applications. These single systems can later be combined to produce a fully functioning interfaces prototype with interactive capabilities. 4.1 INTERACTIVE APPLICATION ELEMENTS Developing simple user input prototype elements demonstrates principles found in the exploratory interactive studies. Simple interactive prototype mechanisms can later be implemented in a variety of scenarios. The first sub-section of the chapter focuses on application examples demonstrating how laser cut device components could enable user interaction through displacement of light. The second sub section expands on how laser cut devices could be used to display meaningful information without the need of electronics situated behind the interface or even projected atop the surface. Prototype elements produced for this chapter: Button light switch Accelerometer Seven-Segment Display o Light sources situated around four sides of display. o Light sources only situated on one side of display. 4.1.1 BUTTON The button element (light switch) was based on interactivity principles discovered from three touch studies performed. It was found that optical sensing could be achieved through push and pressure application to the surface of the material. By embedding optically clear material into an enclosure fitted with a separate light source, a light switch mechanises was produced. The principle input variable for this device was based on light transmission displacement recorded by a standard light-dependent resistor (LDR). The light switch device would be separated into two elements. First, clear Perspex material with light transmitted through it (LED 1) would be used as an actuator that senses user input when pressure is applied to the surface. This would be achieved through Frustrated Total Internal Reflection (FTIR) phenomena and recorded using an LDR sensor positioned below the material. Secondly, a light source (LED 2) would be activated when light intensity readings (LDR with a 10k resistor) reach a specified threshold. This threshold is calculated by sampling light intensity behaviour when pressure is present on the surface of the material. The colour of LED 2 would change depending on the amount of level of pressure applied to the surface. Page 26 of 68 Aluna Everitt SCC.300 2015 Apparatus used: 1. 2x LEDs - first for clear material and second as output to visualise interactivity. 2. 1x LDR - sensing light intensity through material. 3. 1x Arduino Uno - computing interactivity variable. An enclosure was first fabricated by laser cutting three pieces of black material (dimensions: 180x25x3mm). Each of the three layers had specific cavities cut to accommodate three electronic apparatus need for the device. The bottom layer had three cavities to house both LEDs and LDR that would be situated in the two layers above. The middle layer also had three similar cavities. The main cavity of the middle layer (dimensions: 3x5x3mm) was for the LDR sensor. It ensured the LDR would be situated directly below the clear material that would be placed within a frame above. Finally, the top layer consisted of a cavity frame to fit a piece of optically clear Perspex (dimensions: 110x5x3mm) with a slot to fit LED 1 on one side, 50mm away from the LDR cavity. The other slot is cut into the top layer 35mm away from the interactive elements of the device (dimensions: 5x5x3mm) where LED 2 is situated without impacting the light intensity reading from the LDR. The use of LED 2 is predominantly to visually demonstrate user input capabilities. The enclosure was assembled using four nuts and bolts, one situated at each corner of the rectangular enclosure. Once all three electronic components were soldered and placed within the enclosure into their designated cavities an optically clear piece of material was cut and placed within the frame of the top layer, with corresponding dimensions to the frame (110x5x3mm). This material piece could be taken out of the enclosure with ease in order to deactivate the device. Figure 4.1 shows the fabricated button light switch. LDR sensor under transparent material LED 1 light source Clear Perspex Material (110x5x3mm) LED 2 visualising interactivity Figure 4.1: Button light switch when no interaction occurs. Based on the findings from the previous touch studies, light intensity through the material should increase when enough pressure is applied to the surface at a specific point when ambient light is present. The LDR sensor situated directly below the point of contact records light intensity changes when pressure is applied. When pressure was applied directly above the LDR, a 5 second read transmitted every 10 milliseconds (500 sample total) was averaged and used as a threshold for activating LED 2. Subsequently, the same process was applied Page 27 of 68 Aluna Everitt SCC.300 2015 when finger pressure on the surface of the material was relatively light or when the finger was hovering over the surface. The average reading from this second sample was used as the second threshold for activating a different colour light from LED 2 when light intensity decreased. A basic light switch device was designed and fabricated based upon interactive principle discovered during the exploratory touch studies. A simplistic enclosure was designed where clear Perspex material could be placed into a fitted frame. Finger pressure of the user was treated as an independent variable. Light intensity transmission was therefore treated as a dependant variable and used as an input measurement for light switch actuation. User input was achieved by sensing light intensity change caused by FTIR. Using a low-cost LDR discretely situated within the enclosure three threshold sates were used as input variables to activate a light source (LED 2). Hard finger pressure applied to the surface defines high state and LED 2 emits pink light. When light finger pressure is applied low state (decrease in light intensity) is achieved and LED emits yellow light (Figure 4.2). When no finger is present, the device is set to no state and LED 2 is deactivated. Low State Light Intensity Decrease High State Light Intensity Increase Figure 4.2: As pressure on the surface of the material increase LED 2 changes colour from yellow to pink. It was found that these three states could only be achieved when enough ambient light is present in the test environment. When no ambient light is present only two states could be achieved. When any form of pressure is applied to material surface at a point directly above the LDR, light rays are directed towards the receiver hence only allowing for light intensity increase. 4.1.2 ACCELEROMETER A simplistic accelerometer was developed which was actuated through displacement of light guides present within a thin strip of material that was situated in a small black enclosure to avoid ambient light affecting any readings. This device monitors movement displacement from the outside environment. Further displacement is also caused by effects of gravity due to the strip drooping slightly downwards. Page 28 of 68 Aluna Everitt SCC.300 2015 A case enclosure would house a small strip of optically clear material with a wider, heavier section cut on the end in order to enhance the effects of outside motion. A light source would be positioned at one end of the enclosure in a cavity to illuminate the clear strip of material within. A light-dependent resistor (LDR) should be positioned at the other end of the case. As the light-emitting diode (LED) rays travel through the thin material any outside displacement should affect the thin, clear strip. As a result it should move away from the LDR, hence causing a change in light intensity reading. Apparatus: 1. 1x LED 2. 1x LDR 3. 1x Arduino Uno The fabrication of the accelerometer is separated into two sections. First, a small rectangular enclosure was cut from 3mm black Perspex material (dimensions inside: 93x19x19mm). Two openings were cut at each end of the enclosure. The first opening (dimensions: 5x5mm) for situating an LED. The second opening at the other end of the enclosure (dimensions: 5x3.5mm) was cut to accommodate a standard LDR. This rectangular box enclosure was assembled in place with acrylic adhesive. The top section was detachable to enable the placement of the clear material strip. Six vertical sections were etched parallel to each other along the inside walls of the case (dimensions: 4x19x0.5mm). These were used as placeholders for a smaller piece of material that will hold the optically clear strip of Perspex. The small piece of black material was cut separately (dimensions: 20x19x3mm) with an incision measuring 4mm in width and 1mm in height, directly at the centre. This “strip holder piece” was placed securely inside of the enclosure by sliding it into one of the etched sections located within the case. Sensitivity of the accelerometer could be changed by positioning the “place holder” piece closure to the LDR. Secondly, an optically clear strip was cut from 3mm material. The optimal width of cut to ensure flexibility yet durability for the strip was 0.72mm with the length of 94mm. A larger section was cut on the strip, 9.9mm away from the end (dimensions: 5x3mm) in order to enhance the effect of displacement outside. Figure 4.3 shows the accelerometer produced from laser cut material and two active components. Page 29 of 68 Aluna Everitt LED light source SCC.300 Material Strip Holder with incision (20x19x3mm) 2015 Cushion LDR sensor Clear Perspex Material (94x3x0.72mm) Figure 4.3: Accelerometer prototype (top not present) with LED and LDR situated opposite sides of rectangular enclosure. In order to identify any displacement characterisation the independent variable for this study was based on velocity. Firstly the independent variable incorporated vertical velocity by repeatedly shaking the device up and down. Light intensity was considered as the dependant variable and readings were recoded using an LDR for a period of 1.7 seconds. The independent variable changed to incorporate horizontal movement and the device was shaken from left to right on the horizontal axis. Light intensity readings were recorded for 1.7 seconds. Figure 4.4 illustrates the comparison between horizontal and vertical displacement. Figure 4.4: Comparison of vertical and horizontal displacement based on light intensity. The local maxima of light intensity for vertical movement is much higher (200±10 LDR reading) compared to that of movement performed on the horizontal axis (170±10 LDR reading). The device worked relatively well when constant displacement on a specific axis occurred. However, it is difficult to observe the exact behaviour of the material strip as the active components are enclosed within the case. Performance can enhanced if material length was shorter as more light would reach the LDR. Due to high variance in readings throughout prolonged periods of time and lack of touch based interactivity the accelerometer would not be featured in the final application. Page 30 of 68 Aluna Everitt SCC.300 2015 4.2 INTERFACE APPLICATION ELEMENTS Seven-Segment Displays (SSD) visualise meaningful information through individual state transformations of single characters or numerals. Two SSDs were designed and fabricated using laser cut Perspex material. The initial SSD, with seven LEDs around all four sides, was produced to explore light guide manipulation. The initial display illuminated isolated segments in a specified order that mimicked state changes of a conventional SSD. After an efficient design approach was established, a second SSD was implemented where light sources were situated only at the bottom of the display. This chapter details the process of design and fabrication for both displays, including discussion of design decisions made to develop an efficient approach to illuminating various states of an SSD. 4.2.1 INITIAL SEVEN-SEGMENT DISPLAY (LEDS AROUND 4 SIDES) The initial SSD was developed in two stages. First, a 2D vector outline of an enclosure was designed in Illustrator to specific measurements of 85x120x9mm (see Appendix Figure 3). Three layers of laser cut black Perspex plastic (3mm depth) were combined and assembled using 3mm nuts and bolts. The top layer of material was a frame where the clear Perspex display could be placed. Seven LEDs were chained together and interlinked within seven slots of the enclosure. Each LED was specifically positioned within the frame to illuminate only one designated segment (see Figure 4.5). The frame was designed to hold material within the measurements of 65x100mm. Secondly, a number of displays were designed and laser cut out of clear material with depth range from 3mm to 5mm. The observations from the range of laser cut and etched displays can be found below. Transparent display should be situated within the frame (65x100mm) Each LED light source with a number allocated to it Figure 4.5: SSD enclosure (85x120mm) consisting of three layers with LEDs positioned on all four sides. Page 31 of 68 Aluna Everitt SCC.300 2015 4.2.2 INITIAL LIGHTING OBSERVATIONS A range of SSD designs was explored and eight test cases were implemented in order to determine a proficient solution to illuminating isolated segments of an SSD (for full recorded observations see Appendix Table 1). A range of etching styles and depths was also explored to find an efficient approach for enhanced illumination. In an attempt to manipulate light guides a range of cuts with varied widths and positions were also tested. Each segment was uniform in shape (elongated hexagons) and relative to each other in size. In order to observe light distribution effects an individual etches, each segment was scaled to maximum size of 12x37mm in the first four tests. All segments of the display were illuminated even when black tape was applied to the top of active LEDs in an attempt to eliminate any ambient light emitted. Full matt etch are coarse and do not distribute light rays evenly throughout a whole segment. Matt etches reveal the direct path of light from a light source as seen in Figure 4.6. Direct light path from LED light source is clearly visible on matt etches Figure 4.6: Test 1 with five active LEDs illuminates all of the seven segments and visualises light path from LED sources proficiently on matt etches. For light rays to be distributed more consistently throughout each segment a crisscross pattern was designed to defuse refraction. Figure 4.7 shows the initial 2D vector design of the pattern and result. Page 32 of 68 Aluna Everitt SCC.300 2015 2D vector design LED light rays evenly distributed within a segment Figure 4.7: Criss cross pattern etches distribute light rays more consistently compared to flat matt etches. To enhance luminosity of each active segment a range of cuts were made on the surface of the display and impact of illumination for each segment was observed. Diagonal cuts (0.1mm width) correlating to each segment efficiently brightened etched areas closest to the cut as seen in Figure 4.8. This was due to light refracting within air gaps and this intensified the effect of emitted light rays. Real life observations show the right segments illuminated brighter compared to the middle section. Cuts made in close proximity to segments enhance their brightness Figure 4.8: Cuts from test 9 enhances illumination of five segments. In order to isolate light emitted from an LED to a single designated segment, black insertions were designed and placed into the display. The width of cuts was increased to 1mm width and black material (3mm depth) was cut corresponding to cavities in the transparent display. The black material inserts (1mm width) isolated each of the seven sections of the SSD and occluded light rays reaching inactive segments. Several refinements were made to the position and design of the black inserts until a proficient implementation was found. As seen in Figure 4.9 black inserts enable each segment to be illuminated individually without light effective adjacent segments. Page 33 of 68 Aluna Everitt SCC.300 2D vector design 2015 Display produced A singular black insert isolates each segment to reduce number of components needed for assembly Figure 4.9: Design and applied SSD with black material insert that isolates each segment of the display. Black inserts occlude light rays from reaching inactive segments. Further refinements to the design of cuts enabled clear interchangeable states of numerals to be displayed in various colours when ambient light is present as seen in Figure 4.10. Figure 4.10: SSD displaying digits from 0 to 9 in a range of colours in full ambient light. The display is able to visualise each of the 128 states of an SSD with LEDs situated around all four sides of the enclosure. To refine the design further LEDs where positioned only at the bottom of the display. A second SSD prototype was fabricated, using the same design approach, where seven LEDs were situated only on the bottom of the frame. Page 34 of 68 Aluna Everitt SCC.300 2015 4.2.3 REFINED SEVEN-SEGMENT DISPLAY (LEDS ON BOTTOM) Much like the initial SSD, the second display consisted of an enclosure made from three layers of black Perspex material (depth 3mm) with the top layer acting as a frame for a clear display. The prototype was scaled up to a larger size (120x140x9mm) for the enclosure, with frame area 100x120x3mm. Seven LEDs (9mm width each) were soldered to create a sequential chain (length 80mm). Once the LEDs where set up within the enclosure, the design of the initial SSD layout was readjusted to accommodate the new LED alignment. The first redesign of the SSD reflected upon Wills et al. [16] implementation of digital signage, where ten layers are used for visualising individual numeric figures. For the refined SSD two layers of material created an interface that visualised single figures with light sources directly underneath the display. The bottom layer consisted of clear material (5mm depth) divided into seven individual light tubes, one for each segment. Each light tube was situated directly above a designated LED that emitted light rays to a corresponding segment. The light tubes were extended below a selected etched segment. Large cuts were made directly below the etched pattern to intensify luminosity of etched segment above. The top layer was implemented by applying a similar design as the initial SSD. Figure 4.11 shows the two layers SSD with light sources below the enclosure. This implementation provided low luminosity and could be refined further by reducing the number of layers. Top layer etched segment illuminated from light tube situated underneath Bottom layer light tube emitting light to top segment Chain of seven LEDs Figure 4.11: Two layer SSD with LEDs only at the bottom of the enclosure. Page 35 of 68 Aluna Everitt SCC.300 2015 A refined version of the initial SSD display was implemented with a single layer of material (5mm depth) and corresponding black inserts (5mm depth). Elongation of black inserts ensured light emitted from adjacent LEDs did not affect inactive segments (see Figure4.12). In order to fully partition each segment and ensure no light escaped to inactive segments, the display was divided into separate five sections. As this prototype used a frame based enclosure the prototype could stand vertically without any need for adhesive. Two black inserts partition the display into five sections Figure 4.12: Single layer SSD design with black inserts and final implementation of an SSD displaying the figure “4”. 4.3 DISCUSSION AND SUMMARY This section of the report evaluates all prototype elements produced and their purpose for the next stage of application. A breakdown of the design and fabrication process for developing successful SSD displays with light sources situated only on one side can also be found below. Breakdown of design and fabrication process for developing an efficient SSD display: 1. 2. 3. 4. Design simple enclosure in proportion to length of LED strip. Laser cut black Perspex material to corresponding design. Assemble and insert LED strip. Design seven-segment display with enough space between each segment to insert 1mm width black material. o Add lines (1mm width) to partition each segment of the display. 5. Laser cut setting for most effective result for etches and cuts varies depending on material depth please see Appendix Table 1 for details for 5mm depth material. 6. Once the display is cut and etched corresponding cuts must be made to black material of the same depth and inserted into the display where appropriate. Page 36 of 68 Aluna Everitt SCC.300 2015 With influence from the initial SSD design, black inserts are redesigned to accommodate light sources that are situated underneath the display. These interfaces are highly robust and could be submerged in water. Using only one layer of material eliminates the need for electronics to be present in the actual interface. Wills et al. [16] implemented a similar display system using 3D printed rectangular blocks with air pockets. Wills et al. [16] developed a nixie tube style numeric display consisting of numeric figures embedded into ten 3D printed sheets. The SSD interface developed for this project uses one layer of material produce the same outcome with a light source enabling illumination of numeric digits. Figure 4.13 shows a comparison between both displays Figure 4.13: Printed Optics numeric display (a) consisting of embedded air pockets that reflect light when illuminated (b). The numeric display fabricated through laser cutting (c) in contrast only uses one layer of material to visualise figures 0-9. Fabricating interfaces from a single material enables new kinds of cheaper wearable technology to be utilised. The next stage is to apply this design and fabrication process on a smaller scale in order to prove it can be implemented as a transformative process. Using the example of a smart watch ensures the SSD design could be used effectively to display meaningful information on a transparent interface on a smaller scale in a novel manner. In term of interaction, light intensity readings were affected by presence of ambient light within the test environment. If ambient light from the environment was to constantly change the configuration of the device must be monitored and reset to accommodate the ambient light changes. This may decrease accuracy of the device. Nevertheless an algorithm could be computed that eliminates any form of ambient light. Alternatively, an algorithm could monitor changes in the environment (using a separate LDR) and notify a user when ambient light displacement occurs and recalculate threshold levels when pressure is applied and not applied to material surface. This could be done also by adding a compositor to the LDR circuit. In conclusion, the work in this chapter demonstrates prototype elements that can be fabricated as single systems. In order to create a fully functioning prototype both interactive and visual elements must be integrated. In the next chapter this is built on by creating unified prototype interactive watch that is activated through user input to visualise current time. Page 37 of 68 Aluna Everitt SCC.300 2015 5. APPLICATION - WATCH PROTOTYPE This chapter details the design and production of a watch device as a final proof of concept based on the alternative fabrication process developed from preceding chapters. The final prototype integrates application elements from previous studies and applies it in a ubiquitous context to develop a wearable device. This final prototype incorporates the interactive properties of clear Perspex material discovered from the touch studies and button light switch. An interface was conceptualised and developed based on the design and fabrication process used to create an SSD interface. The proposed smart watch should be small in scale and display current time using individual numeric figures sequentially on a single later of optically clear material. An interactive button would be used to activate the display. When a user applies sufficient level of pressure to the surface of the material a change in light intensity, measured by a light-dependent resistor (LDR), will occur. This will be used as an actuation command to display current time on the interface. 5.1 LED ENCLOSURE First, a chain of seven RGB Light-emitting diodes (LEDs) was soldered together. Each LED (dimensions: 5x5mm) was designated to illuminating one segment of the SSD. The total length of the LED chain was 70mm. In future work much smaller surface mount RGB LEDs (dimensions: 3x3mm) could be used to bypass the current limitation of scale. Each LED was 5mm in diameter with a 5mm space between each to limit light dispersion from adjacent LEDs. A rectangular enclosure, consisting of six sides with finger edge joints was designed (see Appendix Figure 6) with seven cavities (spaced 5mm apart) to house each of the LEDs. Black material (3mm depth) was cut into six sides corresponding to the 2D design from Illustrator. Acrylic adhesive was applied to finger edge joints to secure the rectangular enclosure leaving the top side open (dimensions: 90x15x15mm). The LED chain was manually inserted into the enclosure. Figure 5.1 shows the constructed LED enclosure. Black Perspex Material Enclosure (90x15x15mm) LED light source Figure 5.1: LED enclosure for watch prototype with chain of seven LEDs situated inside. Page 38 of 68 Aluna Everitt SCC.300 2015 5.2 INTERFACE The second stage of development involved adapting the previous SSD interface design (dimensions: 100x120x5mm) to a smaller scale for a watch display. Although the enclosure for the LED chain is 90mm in length the interface is much smaller to ensure discreteness as a ubiquitous device. The display integrates a generic SSD interface (dimensions: 40x40mm) with a rectangular extension that increases the length of the entire display by 10mm (see Appendix Figure 7 for design outline). By extending the width to 80mm the display can accommodate the larger enclosure situating the chain of seven LEDs. The whole interface was 5mm in depth and included seven 3mm extensions at the bottom (see Figure 5.2). This enabled the interface to be inserted firmly into the LED enclosure without need for adhesive. Black material inserts Material extension to accommodate chain of LEDs Extension for enclosure insertion Figure 5.2: Refined display for interactive watch prototype. Consisting of optically clear Perspex (depth 5mm) and corresponding black material partitions (width: 0.72mm). The previous SSD design with black inserts was scaled down to accommodate the main 40x40mm interface with an elongated extension. Initially black cuts were simply extended to the bottom of the display to isolate each of the individual LEDs. The width of cut was also decreased to 0.5mm in order to reduce the presence of black material in the interface. The initial display was cut from 5mm clear material with corresponding black material inserts. The whole interface consisted of five separate segments and two black inserts. Acrylic adhesive was used to secure the structure and ensure robustness and stability as a watch. It was discovered that the use of acrylic adhesive disrupted the reflective properties of the clear material when contact was made with the black inserts. This eliminated the reflective edges of the cuts as seen in Figure 5.3. The reflective properties of the display were reduced if too much adhesive was used. Page 39 of 68 Aluna Everitt SCC.300 2015 Area where no adhesive contact is made with the clear black material Area where adhesive makes contact with the clear black material Figure 5.3: Initial watch interface (secured with adhesive to ensure robustness) inserted into LED enclosure. The initial interface design (see Figure 5.4) visualised each of the ten states needed to tell the time using digits 0-9. However the top right segments did not illuminate well compared to the other five segments. This was due to the limiting angle at which the etched segments were located, i.e. 20mm away from their designated light sources. As a result the first display did visualise figures proficiently in ambient light. Even when a darker background was used the luminance of visualisation was not proficient. A fascia was used in an attempt to enhance the visualisation of each etched section. However, the addition of a fascia did not enhance the display as predicted. Comparison of colour and etch observations highlighted current visualisation issues with the initial design. The figures “6” and “9” were illuminated in order to inspect the majority of segments. The refinement of the second interface (see Figure 5.5) was based on visual inspection of angles and position of black inserts and etched sections with correspondence to designated light sources. Page 40 of 68 Aluna Everitt SCC.300 2015 Figure 5.4: Due to angle restrictions the initial design of the display did not allow light to be transmitted efficiently to the top sections as shown by numerals 6 and 9. Certain colours enhanced the visualisation of etched section with more clarity as seen in Figure 5.4. The colour green for figure “6” is much more prominent compared to figure “9” illuminated in yellow. Page 41 of 68 Aluna Everitt SCC.300 2015 A second design was implemented with minor adjustments to angles of cuts and low edge corners to ensure each segment is illuminated proficiently in full ambient light. Figure 5.5 compares prominence of illumination applied using the same figures for consistency. Figure 5.5: Refined design of the display enhanced illumination of both figures regardless of light or dark background and the addition of fascia. The refined design considered angles of each black cut and expands areas of clear material for each sections of the display where light rays struggled to have reached previously. The initial design the colour yellow did not illuminate etched sections proficiently. The refined design enhances the visualisation of each segment even when a yellow light source is used. Page 42 of 68 Aluna Everitt SCC.300 2015 5.3 INTERACTIVE BUTTON A separate enclosure was designed for the interactive button element (dimensions: 90x15x9mm). This was a scaled down version of the original design based on the initial button light switch. The button element could be scaled down even further for future work, however in order to keep aesthetic consistency it was designed to be the same diameter as the LED enclosure (see Appendix Figure 8 for laser cut outline). The button enclosure consists of three layers of black material (3mm depth) with cavities for an LDR to be situated in the middle layer and another cavity for an LED in the top layer. The top layer acts as frame where clear optical material is inserted and is considered an actuator for interactive capabilities. A standard sized LDR was used (dimensions: 5x4x2mm) as smaller LDRs were too sensitive and picked up the frame rate of the LED. A capacitor could also be added in future work to defuse frequency displacement. As the standard LDR did not impact scale is was implanted instead. By excluding the need for a capacitor less electronic components are required. Three layers of laser cut black material are assembled together with active components situated within designated cavities. A piece of clear optical material is cut corresponding to size of the top layer frame (dimensions: 71x5x3mm) and is considered as the actuation component for the interactive button. Figure 5.6 shows the final watch interactive button. LDR sensor Button element enclosure (90x15x9mm) LED light source Transparent material (71x5x3mm) Figure 5.6: Button actuation device consisting of one LED, one LDR, and a strip of optically clear material. User input must be configured, with consideration of ambient light, on the surface of the material. First, light intensity average is calculated when no pressure is applied to the surface, this is used as an actuation threshold for the watch. Secondly, light intensity average is calculated when no pressure applied to the surface. This is used as a threshold to deactivate visualisation if undeliberate interaction occurs. Ambient light in the environment must also be taken into consideration as this disrupts readings from an LDR which is very sensitive. Implementing a compositor in further work could eliminate ambient light noise from LDR reading. Page 43 of 68 Aluna Everitt SCC.300 2015 5.4 FINAL INTEGRATION Once the final interface was assembled a watch strap was designed to hold the watch on a human wrist. The strap design was separated into two sections, one of each side of the display. Hinges secured with adhesive enabled the user to adjust the tightness of the strap. The combined light enclosure, interface, and interactive button produced a wearable watch with interactive capabilities. The interface visualises each digit of current time in sequential order once finger pressure is applied to the button. Performance was tested in ambient light for quality in visualisation and interaction. Interactivity of the button was efficient when used in an environment where ambient light levels did not change. Interactivity of the button did not change when no ambient light was present. Figure 5.7 shows numerical digits visualised on the interface. Each number can be distinctly identified and shown in a range of colours. Due to the incoherent white balance of the camera used (IPad 4 camera) luminance of the display is not as prominent in photographs. Nevertheless visualisation is enhanced when no ambient light is present. A comparison of the display with no ambient light can be seen in Figure 5.8. Figure 5.7: Figures 0 to 9 displayed on final watch prototype in full ambient light. The middle section is no as well illuminated compared the surrounding sections. A range of colours was used to visualise individual digits to examine if certain colours enable figures to be distinguish further. When ambient light is present red, green, and blue colours were more distinguishable as seen in Figure 5.7. However, colour changes had little effect in the visibility of figures when no ambient light was present. Figure 5.8: Figures 0 to 9 displayed with no ambient light present. Each figure is visualised with greater clarity though the middle segment is still less obvious. Page 44 of 68 Aluna Everitt SCC.300 2015 5.5 DISCUSSION AND SUMMARY This chapter demonstrates the integration of singular active prototype elements into a unified watch device with interactive capabilities. The example application proves how laser cut optically clear material can be implemented to fabricate a wearable interactive display. The combination of the LED enclosure, interface and interactive button enabled fabrication of a purposeful interactive device that can be used in both darkness and daylight as seen in Figure 5.9. By applying the design and fabrication process in context of wearable technology it was demonstrated that interface scale should not be an issue in the design space. The main limitation for this application was the large size of LEDs used. This means that the light enclosure could not be discrete. In terms of visualisation, the luminosity of figures could be enhanced further by limiting the space between the LEDs. With further refinements to the discreteness of active components, by using smaller LEDs for example, devices could be scaled down much more. Visualisation of meaningful information on transparent surfaces enables further exploration of design space for new forms of interfaces. WATCH USED WHEN NO AMBIENT LIGHT IS PRESENT WATCH USED WHEN AMBIENT LIGHT IS PRESENT Figure 5.9: Watch used when no ambient light is present compared to when ambient light is present. In terms of interactivity, the button element was able to activate the display when ambient light levels within the test environment stayed constant. If levels of ambient light increased a new threshold levels must be set higher than previously to accommodate the change. Otherwise the button would be activated with the present of ambient light. By adding a capacitor to the LDR circuit ambient light is eliminated from the LDR readings. Page 45 of 68 Aluna Everitt SCC.300 2015 This would mean the addition of an extra electronic component to the fabrication process. An alternative algorithm approach could also be implemented to eliminate effects of ambient light affecting the light sensor. The watch device could easily be customised by simply replacing detachable sections with alternative objects. The transparent display is detachable from the main enclosure. This allows users create new interfaces and replace them easily without the need to fabricate a whole new device. Cost of material and lead time as a result is greatly reduced compared to 3D printing. The design decisions utilised in this report enabled the laser cut devices to have detachable parts. This presents a rapid prototyping process of exploring design decisions without the need to wait for creating a whole new object is enabled as components can easily be replace from an existing object. In conclusion the work in this chapter enables the design and fabrication of a fully interactive watch prototype. The next chapter describes the fundamental process and approach to fabricating interactive display prototypes. Page 46 of 68 Aluna Everitt SCC.300 2015 6. DESIGN CONSIDERATIONS AND DISCUSSION The process of developing interfaces with interactive capabilities described in this chapter consisted of three phases. First, optically clear material light properties were explored for enabling visualisation and interactivity. Secondly, findings and observation were applied to physical examples of single systems. Thirdly, a group of single systems were integrated to produce a functioning interface device with interactive capabilities as a validation of the process described in this chapter. Below the design considerations are presented to design and fabricate interactive interfaces from laser cut Perspex. 6.1 APPARATUS The apparatus consists of a hardware processing board, RGB NeoPixel Mini PCB LEDs (datasheet details can be found below here1), and a standard sized light-dependent resistor (LDR). Use simple transmitter and receiver components. 1. Computer aided design (CAD) software a. 2D vector graphic tool - such as Illustrator. 2. Hardware a. Arduino processing board (such as Uno, Mega, mini, or Nano). 3. For interactive element a. 1x LED for emitting light rays. b. 1x LDR for receiving emitted light rays. 4. For display a. X number of LEDs corresponding to the number of sections required for the display - E.g. seven-segment display use seven LEDs in a chain (one to control illuminate each section individually). 6.2 DESIGN AND FABRICATION OF ENCLOSURE Design an enclosure to house active components in a 2D vector based design space, Illustrator CC used for this project. An enclosure is needed for situating electronic elements. 1. Draw outline of desired enclosure with cavities to expose LEDs and LDR to necessary elements. 2. Base the design of enclosure on the size and measurements of active components. 3. Draw small cavity (for LDR) underneath clear material used for interactive elements. 4. Simple layer three structure recommended: a. Top layer for exposing light emitting components (LEDs) for display and housing optically clear material for interaction. b. Middle layer for exposing light intensity receiver (LDR). c. Bottom layer for support of active components. 5. Draw four holes for each corner of each layer which correspond with each other for nuts and ballots to hold entire enclosure in place securely. This is the easiest design approach for assembly, reassembly, and replacing components if needed. 1 https://learn.adafruit.com/downloads/pdf/adafruit-neopixel-uberguide.pdf Page 47 of 68 Aluna Everitt SCC.300 2015 6. Prepare laser cutter setting (for LaserPro Spirit GE please see Appendix Table 2) a. Use higher power and low speed for cuts. b. Use relatively high power and high speed for etches (for example: labels on top layer of enclosure). 1. Use black Perspex material for enclosure as ambient light and stray emission from LEDs is absorbed rather than reflected. a. Recommended depth of material more than 3mm for robustness. 2. Once each layer of enclosure is cut and etched where appropriate combine each layer in sequential order on top of each other. 3. Manually insert active components within their designated cavities. 4. Clear optical material should not be embedded into the enclosure but instead the enclosure will be used to support a display which is detachable. 5. Once each layer or side of enclosure is cut assembly depending on initial 2D design a. If holes are used for assembly, use nuts and bolts to hold enclosure object structure firmly in place corresponding width of holes. b. If finger edge joints are used it is recommended to apply acrylic adhesive for best results and hold structure firmly in place. c. Clear super glue could also work well. 6.3 DESIGN AND FABRICATION OF DISPLAY The display is considered to be a separate element of the device which can be inserted on top of the enclosure where cavities for the display’s LEDs are positioned. The display can be scaled up or down depending on the needs and specifications. 1. Draw outline of display 2D vector based design software (such as Illustrator). 2. Draw segmented design that corresponds to the number of LEDs. a. Use full colour fill for areas of display which are to be illuminated – these will be etched – recommended for etching is crisscross pattern as light rays are distributed more evenly throughout all of the section without illuminating the direct path of light source - Each section of display which is to be visualised individually. 3. Draw lines of no more than 0.72mm. a. The minimum thickness of the blocking material is limited by its material properties. Specifically it was observed that even black opaque Perspex behaves like a translucent material when cut into thin slivers (<0.72mm thick) 4. Each path of cut should isolate an individual section of the display. 1. 2. 3. 4. Optically clear Perspex material (depth no more than 1mm – for robustness). Cut and etched transparent material using 2D vector design. Cut inserts corresponding to cuts made in display from black material of same depth. Manually situate black material inserts into clear display. Page 48 of 68 Aluna Everitt SCC.300 2015 5. Secure structure with clear adhesive if necessary. Aim to use as little as possible so as not to disrupt reflective properties of any edges. 6.4 PROGRAMME DISPLAY Each light-emitting diode (LED) must be designated to a single segment (see Figure 6.1). It is not necessary to use multi-coloured LEDs. However, colour changing visualisations provide an extra dimension of clarity when displaying sequential information using just one SSD. Figure 6.1: To display numeric figure “3” LEDs 3, 4, 5, 6, and 7 must be active whilst LEDs 1 and 2 must be inactive. Multi coloured LEDs are activated and set colour using three input variables – red, green, and blue (RGB). Figure 6.2 shows basic sequence of active and inactive states of each LED to display numeric figure “3” in green. An Arduino Adafruit NeoPixel library function is used for controlling single-wire-based LED pixels and strips of LEDs. // Activate LEDs pixel_01.setPixelColor(2, pixel_01.Color(0, 255, 0)); // LED 3 pixel_01.setPixelColor(3, pixel_01.Color(0, 40, 0)); // LED 4 less luminance for consistency pixel_01.setPixelColor(4, pixel_01.Color(0, 255, 0)); // LED 5 pixel_01.setPixelColor(5, pixel_01.Color(0, 255, 0)); // LED 6 pixel_01.setPixelColor(6, pixel_01.Color(0, 255, 0)); // LED 7 // Inactive LEDs pixel_01.setPixelColor(0, pixel_01.Color(0,0,0)); // LED 1 pixel_01.setPixelColor(1, pixel_01.Color(0,0, 0)); // LED 2 Figure 6.2: Example Arduino processing code for visualising numeric figure “3”. Page 49 of 68 Aluna Everitt SCC.300 2015 6.5 PROGRAMME INTERACTIVE ELEMENT 1. Take sample of light intensity when no pressure or contact is applied to surface of clear material a. Find average of at least 500 samples to eliminate chance of anomalies b. Use average as threshold when no user input is present 2. Take sample of light intensity when low pressure contact is applied to surface of material a. Find average of at least 500 samples to eliminate chance of anomalies b. Use average as threshold for first user input variable 3. Take sample of light intensity when high pressure contact is applied to surface of material a. Find average of at least 500 samples eliminate chance of anomalies b. Use average as threshold for second user input variable 6.6 DISCUSSION AND SUMMARY The main aim of this project was to contribute an alternative approach to designing and fabricating interfaces with interactive capabilities. Based on initial explorations of light properties a simplistic method of designing and producing interactive elements and visuals displays has emerged. By integrating active comments a fully functioning watch prototype was implemented. The process described in this chapter outlines fundamental techniques for designing and developing such active components that can be customised and altered to an individual’s needs and specifications. Laser cutting enables a low cost and accessible method of fabricating rapid prototypes. As a result a rapid process of exploring design decisions without the need to wait for creating a whole new object has emerged. Electronic components and material used throughout this project are low cost and easily implemented without need for low level techniques skills. And design space demonstrated within this project can be elevated further by exploring with a large scope of interactive interface applications. The process described enables a creative approach to the design and fabrication of interfaces that could be implemented by a large range of users who do not have access to high cost optical 3D printers or poses high level 3D modelling knowledge. Design space could be further extended to 3D curved displays with the use of light pipes of different depths. The main limitation of the current system is that user input threshold light intensity must be calibrated manually when ambient light intensity within the environment changes. The stability of interactive devices fabricated using the process presented is limited if constant resets are needed to calculate user input threshold. An algorithm could be implemented to eliminate ambient light data from LDR readings. Alternatively, a capacitor could be added to the LDR circuit which would also eliminate ambient light readings. The addition of a capacitor however, would mean an extra electronic component is added to the fabrication process. Page 50 of 68 Aluna Everitt SCC.300 2015 In an attempt to capture how the general public would react to the novel interfaces developed the prototypes were demonstrated in three consecutive sessions. In the wild observations were written down based on unpremeditated feedback in an attempt to understand how people respond to new forms of novel interfaces with interactive capabilities. Figure 6.3 comprises of words and phrases frequently mentioned when demonstrating prototypes produced from this project across three consecutive sessions. Figure 6.3: Word cloud of key phrases and words taken from observations conducting during open day demonstrations. Overall the unstructured feedback received from the general public was positive. Greater interest was shows in the visual aspects on the prototypes demonstrated. This was mainly due to the bright colours and high luminosity emitted that attracted higher interest. A number of suggestions for possible application of this technology were suggested such as car windscreen clocks and window displays. There was also excitement at the concept of implementing such interfaces in social night club environments. Each of the steps demonstrate the design and fabrication of individual components can be integrated in create an interface display with interactive capabilities. The watch prototype described and implemented shows that functioning interactive interfaces could be produced with a limited number of active components using laser cutting techniques. The conclusion chapter revisit objectives declared at the start of this report and analyse the solution outlined throughout this project. Current limitations and future work is also discussed. Page 51 of 68 Aluna Everitt SCC.300 2015 7. CONCLUSION This project demonstrated an alternative approach for rapid prototyping of novel interactive interfaces. Using low cost and highly accessible optically clear Perspex material and adding interactivity using basic light receiver sensor and light emitter. The design considerations for this process should enable replication of similar devices. Extending this, alternative novel approaches to interface implementation could also be explored by following the five inclusive steps described previously. The use of a laser cutter enables rapid fabrication of prototypes without the need of high level knowledge of 3D modelling. Perspex material used for this project can be easily obtained at low cost and offers higher quality finish compared to resin, Acrylonitrile Butadiene Styrene (ABS), or Polylactic Acid (PLA) used for 3D printing. 7.1 REVIEW OF AIMS The initial aims of project have been successfully met. A general approach was presented for using laser cut Perspex prototype elements to display information and sense user input. Techniques for visualising information using laser cut optically clear material, including use of etchings and cuts to enhance luminosity of displays can be demonstrated by the implementation of three varieties of seven-segment displays. Techniques for sensing user input with laser cut transparent material were demonstrated through the application of a button light switch and accelerometer. This involved touch pressure input with an embedded sensor and manual displacement of light wave guides. An example application watch prototype demonstrated how laser cut optically clear material could be implemented to fabricate a wearable interactive display. 7.2 LIMITATIONS In depth explorations of light studies should be conducted to ensure a more developed understanding of light properties of optically clear Perspex plastic. Smaller LEDs for visualisation and interactive purposes could be used to further scale down size of devices fabricated. Refinement of etching style on the surface of the material could also enhance valuation of information displayed. A varied range of applications should be designed and tested to uncover limitations of laser cutting interactive prototypes. Only flat displays were fabricated and this limits current knowledge of possible implementations of curved and 3D surface displays. Optical properties of materials other than Perspex should also be explored in order to extend current findings from this project to a larger scope. When ambient light is present certain segments are occluded by others and do not illuminate as prominently. Further explorations of interface design must be made to enable enhanced visualisations of information without any inconsistencies. The laser cutter used throughout this project also varied in quality and precision of cuts and etches due to maintenance issues. As a result laser induced damage to the material decreased quality of optical illumination. Page 52 of 68 Aluna Everitt SCC.300 2015 7.3 FUTURE WORK Although the original aims of this project have been met, further refinements and extensions of studies can be implemented in the future. Implementation of alternative interface designs with curved surfaces and extrusions would contribute to current fabrication process available in the field. Extending light studies by exploring effects of light intensity in a range of widths and scales of material would build upon current understanding of optical light properties of Perspex. Algorithmic implementations of interface designs should also be considered in future work. A 2D vector design system could be developed where users draw their interface segments have black insert cuts algorithmically generated. With reference to Aurenhammer [1] Voronoi diagrams geometric paths could be computed in order to isolate each segment based on the nearest neighbour concept as seen in Figure 7.1. This would reduce the need for a user to manually design black insert cuts for an interface. Figure 7.1: Voronoi diagram isolating each of the eight points with maximum space around each centre. 7.4 LEARNING OUTCOMES Throughout the duration of this project a range of skills and knowledge was obtained. I have encountered new forms of prototype fabrication with the support of Computer Aided Design (CAD). I now have proficient knowledge of operating a laser cutter for a wide range of applications. My knowledge of electronics and circuit board implementations has enabled me to not just design devices but also produce rapid high fidelity prototypes efficiently. My Arduino programming skills have greatly aided the progress of this project and have been further enhanced through the range of applications used such as conducting lighting studies and visualising meaningful information using just seven LEDs. This project enabled me to explore new possibilities for interactive interfaces and sensors using simple laser cutting techniques. Overall the process derived from this project successfully enables a novel approach to fabricating interactive interfaces and sensors using simple laser cutting techniques and two electronic components (light source and light sensor). Page 53 of 68 Aluna Everitt SCC.300 2015 BIBLIOGRAPHY [1] Aurenhammer F. (1991) Voronoi diagrams—a survey of a fundamental geometric data structure. ACM Computing Surveys (CSUR), 23(3), 345-405. [2] Baudisch P., Becker T. & Rudeck F. (2010, April). Lumino: tangible blocks for tabletop computers based on glass fiber bundles. In Proceedings of the SIGCHI Conference on Human Factors in Computing Systems (pp. 1165-1174). ACM. [3] Bergman D. J. and Stockman M. I. (2003) Surface plasmon amplification by stimulated emission of radiation: quantum generation of coherent surface plasmons in nanosystems. Physical review letters, 90(2), 027402. [4] Blöchl P. E. (1994) Projector augmented-wave method. Physical Review B,50(24), 17953. [5] Brockmeyer E., Poupyrev I. & Hudson S. (2013) PAPILLON: Designing Curved Display Surfaces With Printed Optics for USIT (2013). [6] Han J. Y. (2005). Low-cost multi-touch sensing through frustrated total internal reflection. In Proceedings of the 18th annual ACM symposium on User interface software and technology (pp. 115118). ACM. [7] Han J. Y. (2008) U.S. Patent No. 20,080,284,925. Washington, DC: U.S. Patent and Trademark Office. [8] Lin R. (2003) U.S. Patent No. D469,089. Washington, DC: U.S. Patent and Trademark Office. [9] Mader A., Dertien E. & Reidsma D. (2012) Single value devices: In Intelligent Technologies for Interactive Entertainment (pp. 38-47). Springer Berlin Heidelberg. [10] Mueller S., Kruck B. & Baudisch P. (2013) LaserOrigami: laser-cutting 3D objects. In Proceedings of the SIGCHI Conference on Human Factors in Computing Systems (pp. 2585-2592). ACM. [11] Orchard A. R. (1993) U.S. Patent No. D337,104. Washington, DC: U.S. Patent and Trademark Office. [12] Rümelin S., Beyer G., Hennecke F., Tabard A. & Butz A. (2012) Towards a Design Space for Non-Flat Interactive Displays. In ITS (2012) [13] Savage V., Schmidt R., Grossman T., Fitzmaurice G. & Hartmann B. (2014) A Series of Tubes: Adding Interactivity to 3D Prints Using Internal Pipes For UIST (2014) [14] Suman M. J., Welling T. L. & Schneider R. J. (1998) U.S. Patent No. 5,822,023. Washington, DC: U.S. Patent and Trademark Office. [15] Takada Y., Kanagawa K., Nakabayashi R. & Kanagawa K. (2012) Ficon: a Touch-capable Tangible 3D Display using Optical Fiber. In ITS (2012) [16] Wills K., Brockmeyer E., Hudson S. & Poupyrev I. (2012) Printed Optics: 3D Printing of Embedded Optical Elements for Interactive Devices for UIST (2012) Page 54 of 68 Aluna Everitt SCC.300 2015 APPENDICES PROTOTYPE ELEMENTS Appendix Figure 1: Button light switch enclosure design outline. Appendix Figure 2: Accelerometer enclosure outline. Page 55 of 68 Aluna Everitt SCC.300 2015 SEVEN-SEGMENT DISPLAY CHAPTER Appendix Figure 3: Enclosure for initial SSD with cavities for LEDs to be situated on all four sides of the display. Appendix Figure 4: Enclosure for second SSD with cavities for LEDs to be situated only on the bottom of the display. Page 56 of 68 Aluna Everitt Test # 1 Etch/Cut Etch SCC.300 Speed 60 Power PPI 70 500 Material Depth 3mm Etching Type Matt LED Image Birghtness 100 2015 Result Result Comments Real Life: Etched edges closest to LEDs are brightest - can see direction of light rays on fully matt etched surface panning out - middle segment not obvious - very hard to differentiate between segments which are intended to be on and off Photo Result: Illumination of segments more prominent compared to real life light does not fill whole segment - issue with illuminating middle segment Need guide and manipulate light waves 2 Etch 60 40 625 3 Cut (16) 1 75 400 3mm Dots 100 Same as Test 3 but without middle cuts 100 Real Life: Display still not obvious enough - cuts in plastic guide light more reflection and more illumination display is very bright - very hard to make out any difference 4 Etch 60 50 625 3mm Dots 100 Photo Results: Pretty much the same as real life 5 6 Cut (0.01 inch) Etch 1 60 100 50 1500 625 100 3mm Matt 100 Real Life: Matt etching works better more obvious which segments are illuminated - could enhance further interesting reflection behaviour for middle section - cuts guide the light waves efficiently - the middle segment is illuminated more obviously Photo Results: Contrast is more emphasised due to white balance in the camera - effect of illumination more prominent 7 Cut (0.01 inch) 1 100 1500 8 Etch 70 50 625 3mm Dots 100 Matt/ Dots 100 Same as Test 3 Real Life: Outside section illuminated more prominently - middle section not as much - display overall very bright need less light by having less cuts? Photo Results: middle section much better shown in photo than in real life Appendix Table 1: Visual observational findings from initial SSD design explorations with power and speed used. Page 57 of 68 Aluna Everitt SCC.300 2015 Appendix Figure 5: Single layer SSD display were LEDs are situated at the bottom. Etch Cuts Speed 80 0.7 Power 90 100 PPI 1000 1500 Appendix Table 2: Most effective setting for cutting and etching Perspex Material (5mm depth) for SSD display Page 58 of 68 Aluna Everitt SCC.300 2015 WATCH CHAPTER Appendix Figure 6: Watch prototype LED enclosure laser cutter design with cavities on top side for LEDs. Appendix Figure7: Final watch display laser cut design. Appendix Figure 8: Button for watch laser cut design. Page 59 of 68 Aluna Everitt SCC.300 2015 PROJECT PROPOSAL Illuminative interactive interfaces are becoming more prominent as the manipulation of optics2 is becoming an integral part of sensing, display and illumination of interactive devices. This project proposes a design model which enables the development of various novel interfaces with emphasis on using an easily accessible medium of Perspex sheets and laser-cutting. One of the main aims of this project is exploring the relationship between light waveguides using frustrated total internal reflection (FTIR3) and by laser-cutting Perspex to desired specifications. As a result of the lighting experiments, the project aims to generate an accessible design model which end-users are able to adopt with ease and flexibility to construct interfaces for particular needs. Understanding the relationships involved with lasercutting reflective behaviour and diffusive properties of light interaction with etched surfaces, all account towards establishing a primary model that end-users are able to understand and implement. This project aims to design and implement a variety of novel interfaces through modelling light waveguides and constructing them via laser-cutting and etching with capabilities of direct user input via touch sensing. Establishing principles for a design model is the main focus of the project. End-users, who wish to create novel illuminative interfaces via laser cutting and etching, can also implement their ideas with ease via the developing design model. This report covers the background of how novel interfaces are created using manipulated optics, frustrated total internal reflection, laser cutting techniques and manual ray tracing. In the background section there is also discussion on how the current research can be implemented and further developed through this project in order to surpass limitations. The proposed project section covers details regarding the methods used to develop the indented novel interfaces and the experimental elements of the study. Specific details of the main objectives and a breakdown of the phases required to complete the project can be also be found as well as a Gantt diagram showing the breakdown of tasks. Required resources are also listed as well as references used for this report. 2 + 3 Printed Optics: 3D Printing of Embedded Optical Elements for Interactive Devices - Karl D.D. Willis - Eric Brockmeyer - Scott E. Hudson - Ivan Poupyrev 3 Frustrated Total Internal Reflection: A demonstration and review http://www.cleyet.org/Misc._Physics/Microwave-Optics/Evanescent-FTIR/FTIR%20review.pdf 15/05/2014 Page 60 of 68 Aluna Everitt SCC.300 2015 With recent innovation in optical quality 3D printing, it is now possible to construct novel interfaces designed for specific needs and purposes. There is now emphasis on creating devices that can be modelled as a single object without the need to have individual circuit boards and assembly parts. 3D Printed Optics4 now allows for rapid prototyping of interactive devices with fabrication techniques such as Sensing Displacement embedded within devices during their creation. Sensing Displacement is a fabrication technique that uses an infrared emitter that releases light rays through a transparent material (Perspex for instance) which can be recorded by an infrared receiver. The IR receiver is able to register high or low readings and from these can determine if there has been any physical interaction made on the surface of the device. 3D printing is predominantly a high cost technique that is rarely accessible to most people whereas the proposed use of laser-cutting and etching would produce the desired effect at a lower cost and in less time. Sauron5 is an embedded single-camera sensing for printing physical user interfaces that aids designers in developing prototypes that are ready action objects. With minimum assembly and wiring, Sauron assists designers in creating rapid prototypes that are interactive from the start. With inspiration from Sauron’s system this project also aims to develop a model that can relate to principles of rapid prototyping of active objects by deriving possible interactive elements of devices early on in the design process. As this project will entail the use of laser-cutting as opposed to 3D printing, which is more expensive in monetary terms, it is key to explore different possibilities for using the laser cutter. A concept inspired by research Stefanie Mueller into LaserOrigami6 can prove to be an aid when designing and assembling novel interactive devices for this project. LaserOrigami is a rapid prototyping system that produces a 3D object via a laser cutter, this is a much faster fabrication technique compared with 3D printing and even standard lasercutting as there is no manual assembly. Although the prototypes created through LaserOrigami are static objects, the techniques for fabrication can aid the design and assembly of devices for this project. Frustrated Total Internal Reflection was first developed for interactive multi-touch tables by Jeff Hans7 . As light enters the core of a transparent material the ray is reflected through the core if the wave strikes a medium boundary at an angle larger than that of the angle of the surface boundary. 5 Sauron: Embedded Single-Camera Sensing of Printed Physical User Interfaces - Valkyrie Savage, Colin Chang, Bjorn Hartmann - 2013 6 LaserOrigami: Laser-Cutting 3D Objects - Stefanie Mueller, Bastian Kruck, and Patrick Baudisch - 2013 7 Low-Cost Multi-Touch Sensing through Frustrated Total Internal Reflection – Han, J. Y 2005 (In Proceedings of the 18th Annual ACM Symposium on User Interface Software and Technology) Page 61 of 68 Aluna Everitt SCC.300 2015 As shown in Figure 1 any interaction/frustration with the outside of the surface causes light rays within the core to escape from the boundaries into the air. This project will adapt FTIR to different technologies, such as wearable devices, instead of just interactive tables. Diagram of a finger touch that is used to frustrate the light waveguide – FTIR *Taken from: http://cs.nyu.edu/~jhan/ftirsense/ The main aim of this project is to develop novel displays with input capabilities through laser-cutting Perspex plastic to construct and model light waveguides. This project will focus on using laser-cutting and Perspex plastic as opposed to 3D printing as it is considered to be more accessible to most people. With the fabrication of successful novel interfaces complete, it will also be beneficial to explore how end-users would be able to implement their own ideas via laser-cutting and etching in an efficient and affordable way. By exploring and understanding patterns from lighting experiments conducted at the start of this project a variety of prototypes with input functionality will be developed. Each successful prototype will be evaluated and compared against one another in order to establish a model of design patterns that can be implemented for specific requirements and this will result in a design model represented via an infographic. Light Experiments List of Behaviours and Patterns Design Model (Infographic) Prototype 1 Prototypes Prototype 2 This diagram represents the workflow of this project Prototype 3 Project Report Page 62 of 68 Aluna Everitt SCC.300 2015 These novel displays will be constructed by laser-cutting and etching Perspex plastic sheets and applying LED lights to one end of the cut transparent plastic, modelling specific light waveguides that can manipulate photons to illuminate particular areas when needed to display graphics. The user will be able to touch the surface of the plastic directly. This in turn will disturb the light rays and cause them to scatter outside of the core of the Perspex. This change in the light ray behaviour (intensity/direction/destination) can be used as an input variable for interaction detection. The project will involve two main phases. Beginning with experimenting and establishing behavioural patterns of visible light interacting with Perspex via ray-tracing and manipulating FTIR8 elements, a model of similar patterns can be observed. This design model will form principles that shall aid the creation of prototypes in the second phase of this project. An optional additional third phase can be implemented for user evaluation and focus group testing on the design model. Activity 1 - The familiarisation of laser cutter in order produce quality laser cut objects. Explore different laser cuts and etching techniques to establish the core foundation for the project. Activity 2 - Understand how light rays can be manipulated to produce a desired result of specified illumination. This is one of the key aims of this project. By using etching to defuse reflections and laser-cutting to construct pathways for reflection and refraction, this project will explore how laser-cutting Perspex in particular ways can affect light intensity and illumination. The recorded results of this activity should produce a list of behaviours and their characteristics. Activity 3 – Deliver interaction using Frustrated Total Internal Reflection (FTIR), where the scattered light ray readings recorded by the IR receiver can be used to manipulate the interface by changing the paths of light rays traveling through the core of the Perspex. A small Arduino can record the input transmitted by the IR receiver or even a Light Dependent Resistor (LDR) and visualise the results. Activity 4 - Generate an infographic/diagram representing the patterns and relationships found between etchings, laser-cutting and light intensity. This will inform the development of prototypes in phase two. 8 http://wiki.nuigroup.com/FTIR Page 63 of 68 Aluna Everitt SCC.300 2015 The second phase of the project will involve creating functional prototypes. Activity 5 - Establish templates for a functional set of prototypes which correspond to patterns found in the lighting experiments conducted in phase one. Activity 6 - Create prototype one. Activity 7 - Create prototype two. Activity 8 - Create prototype three. Activity 9 - This is the final activity of the project and will conclude with a written report of all findings gathered from this project. The novel interfaces will include touch sensitive wearable technology such as a bracelet (Figure 3), which could implement multiple input capabilities9 10. This will be done by using Frustrated Total Internal Reflection (FTIR) to manipulate light waveguides to avoid occlusion as the light source would be at the back of the bracelet while the illuminations will occur at the front, where the user is able to view the display. In addition to this example, an interactive keyboard may also be developed by modelling light waveguides to specifications and using a “planar waveguide11” system made from Perspex that is laser cut and etched. This illuminative keyboard will be capable of display a QWERTY style keystroke layout with input and output functionality through the frustration of light rays trapped within the “core” of the Perspex. These are just two examples of possible interfaces that can be Possible design for an interactive developed using simple Perspex material and laser-cutting. rd The 3 prototype developed for this project will take into bracelet account a variety of possible interactive displays that can be created. 9 http://www.prnewswire.com/news-releases/interactive-led-wristbands-are-lighting-up-shows-and-events258647261.html 17/05/2014 10 http://www.ecouterre.com/the-dial-is-an-illuminated-rotary-phone-for-your-wrist/dial-phone-bracelet-2/ 17/05/214 11 http://electron6.phys.utk.edu/light/10/light_guides.htm 15/05/2014 Page 64 of 68 Aluna Everitt SCC.300 2015 This phase is only feasible after the project has secured successful results from the first two phases and there is still time to implement additional work for this phase. This 3rd phase will involve implementing a framework system, which can be presented to a focus group. The focus group will be able to evaluate the system and their feedback will establish key principles of how end-users intend to develop their own ideas into specific novel interfaces. A design workshop will uncover the functional and non-functional requirements of such a modelling system through a focus group review. Illuminative interfaces have the potential to stimulate the users both visually and physically, but they lack a design model which would aid their construction. As a solution to this problem, this project aims to generate a series of tests that explore the manipulation of light waveguides, light reflection and refraction within the core of Perspex plastic. Exploring how Frustrated Total Internal Reflection (FTIR) can be best implemented in order to allow the use of the Perspex surface as an input mechanism. Although many interactive object oriented interfaces employ the use of 3D printing as their primary tool, 3D printing is still highly inaccessible and expensive for public use. Perspex plastic is more accessible and cheaper in terms of size compared to 3D printer filament and resin (for gluing). A laser cutter can implement the same geometric properties to a shape as a 3D printer but a lot faster also. It is clear that the use of laser-cutting and Perspex material is more cost efficient compared with 3D printing as well as easier for end-users to create their visions via laser cutting. Page 65 of 68 9 8 7 6 5 4 3 2 1 Activity Number Write Project Report discussing all relevant findings Implement functional prototype 3 Implement functional prototype 1 (Bracelet concept possibility) Implement functional prototype 2 (Keyboard concept possibility) Familiarise laser cutter and construct basic primitives from laser-cutting Perspex Experiment with etching and lase-cutting to uncover behavioural patterns Explore FTIR input and interactivity capabilities Develop design model that can be applied to rapid prototyping Establish working pattern that can be applied to various prototype concepts Task Description W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17 W18 W19 W20 Aluna Everitt SCC.300 2015 Page 66 of 68 Aluna Everitt 1. 2. 3. 4. SCC.300 2015 Access to Illustrator and other vector based software for design of interfaces Prototype modelling via 3D software such as AutoDesk Inventor Access to laser cutter Electrical components needed include: o Arduino – For control and readings o LED lights (IR emitters) o IR receivers o Light Dependent Resistors (LDR) Papers: Printed Optics Printed Optics: 3D Printing of Embedded Optical Elements for Interactive Devices by Karl D.D. Willis, Eric Brockmeyer, Scott E. Hudson and Ivan Poupyrev – 2013 Frustrated Total Internal Reflection (FTIR) Frustrated Total Internal Reflection: A demonstration and review by S. Zhu, A. W Yu, D. Hawley, and R. Roy – 1985 Low-Cost Multi-Touch Sensing through Frustrated Total Internal Reflection by Han, J. Y - 2005 (In Proceedings of the 18th Annual ACM Symposium on User Interface Software and Technology) Sauron Sauron: Embedded Single-Camera Sensing of Printed Physical User Interfaces by Valkyrie Savage, Colin Chang and Bjorn Hartmann – 2013 LaserOrigami LaserOrigami: Laser-Cutting 3D Objects by Stefanie Mueller, Bastian Kruck, and Patrick Baudisch – 2013 Websites: Light Waveguides http://electron6.phys.utk.edu/light/10/light_guides.htm Sourced - 15/05/2014 Frustrated Total Internal Reflection (FTIR) http://cs.nyu.edu/~jhan/ftirsense/ Sourced - 15/05/2014 http://wiki.nuigroup.com/FTIR Sourced - 18/05/2014 Page 67 of 68 Aluna Everitt SCC.300 2015 Prototype Concepts Inspiration http://www.prnewswire.com/news-releases/interactive-led-wristbands-are-lighting-up-showsand-events-258647261.html Sourced - 17/05/2014 http://www.ecouterre.com/the-dial-is-an-illuminated-rotary-phone-for-your-wrist/dialphone-bracelet-2/ Sourced - 17/05/2014 LaserOrigami http://stefaniemueller.org/ Sourced – 17/05/2014 Page 68 of 68