Three Cut Problem

(conceived by
beloved Professor Edward Zagorski)

Experiential discovery of form.
Practice in aesthetic appreciation regarding the relationship of all parts to each other.

The student will learn how to create form in an abstract way while learning how to use the band saw and finish a piece of wood to finish-model craftsmanship levels.

Create a form you have never seen before, and prepare it as you would a product model.

Purpose:

1. Form First – manipulate form and discover an aesthetic
2. Discover you can create form without drawing it ahead of time
3. Bauhaus principles: How far can you carry your tools?
4. Discover that form can have no function, but possess beautiful appeal as a piece of sculpture
5. Recognize form discovery can lead to product design
6. Consider how the solution is to be mass-produced
7. Realize your process must be communicated if someone else is to successfully reproduce your solution [orthographics, sections, exploded views, full-size patterns, photos]

Constraints:

1. Specified size of material block: 4” x 4” x 10”
2. Must cut more than once, but cannot make more than three cuts
3. Rearrange all pieces to create another form
4. Must use all parts
5. Sand all parts without reducing
6. Finish with lacquer in designer’s choice of color(s)

Tools:

1. Band Saw
2. 1/8” band saw blades (Students will test the turning radius limits of the blade, therefore, be prepared to break a few.)
3. Clamps
4. Spray Booth and means to spray sanding sealer, primer and finish coat

Materials:

1.   Balsa Foam [several 4” x 4” x 10” blocks]
2.   Basswood    [(1) 4” x 4” x 10” block] (Bass wood is preferred, but any low-grain wood will work)
3.   Masking tape
4.   Hot glue gun and hot glue
5.   Tight-Bond wood glue
6.   180 grit sandpaper, 320, 400 and 600 wet/dry sandpaper
7.   Tack Cloth
8.   Sanding sealer
9.   Lacquer based primer
10. Lacquer based paint

Process:          

A. Preliminary experimentation
1. Begin by reviewing band saw operations
2. Experiment using 4’ x 4” x 10” balsa foam
    a. make a cut (This can be straight and uni-directional or multi-directional, curved, or a combination)
    b. rearrange the two pieces and tape them together (shift, juxtapose, rotate, flip - you do not have to tape them back together in the same configuration they came from)
    c. make a second cut through the taped-together object (this can be straight and uni-directional or multi-directional, curved, or a combination)
    d. using tape, tape the two newly cut pieces back together. (shift, juxtapose, rotate, flip - again, you do not have to tape them back together in the same configuration they came from.)
    e. make a third cut. (optional to stop cutting after two cuts) (this can be straight and uni-directional or multi-directional, curved, or a combination)  
    f. remove all tape and lightly sand all pieces with 120 grit sandpaper.
    g. manipulate the form by rearranging the pieces until you discover an aesthetic.  Stop when you think it is right.
    h. assemble all pieces using hot glue

B. Final Presentation  
1.   Repeat preliminary step 2a – 2g using 4” x 4” x 10” block of  Basswood.  [may need to spot glue with Tight-Bond glue in place of using tape in steps b. and d.]
2.   Using Tight-Bond glue and clamps, assemble final form. [may use dowel pins where necessary]
3.   Seal with first coat of sanding sealer and let dry.
4.   Sand surface with 120 grit sandpaper.
5.   Seal with second coat of sanding sealer and let dry
6.   Sand with 320 wet/dry sandpaper
7.   Seal with third coat of sanding sealer
8.   Sand with 400 wet/dry sandpaper
9.   Seal with fourth coat of sanding sealer
10. Sand with 600 wet/dry sandpaper
11. Prime with lacquer based primer (one or two coats)
12. Paint with lacquer based paint (one or two coats) any color or two colors

C. Create a set of working drawings

Assessment Criterion:
1.Craftsmanship
2.Aesthetic Sensitivity

Time Table:
1.Product Introduction
Wed, October 4
2.Balsa Foam Experimentation
Mon, October 9
3.Form Conclusion
Wed, October 11
4.Basswood Production
Mon, October 16
5.Sanding Sealer Application
Wed, October 18
6.Final Finish Application
Mon, October 23
7.Presentation
Wed, October 25