Chainmail Weaving Method Diagram.
While creating # armour, I experimented with various materials to determine the most effective way to express the sense of security and restriction it brings. I first tested a weaving method using a metal box as the square base and elastic bands for the circular connections. While the bands offered flexibility, they only allowed one-way weaving and often retracted unevenly, causing misalignment. This experiment revealed the need to refine both material choice and construction technique.
To improve on the limitations of the elastic band version, I replaced them with paperclips in the next experiment. By attaching four paperclips to the corners of a square frame, I was able to extend the structure using their dual openings. This solution fixed the alignment issues and added greater stability. The metal also helped maintain a clear and consistent pattern across curved surfaces. However, the resulting form lacked the visual clarity of a hashtag (#) shape, which remains a key challenge.
I began exploring new possibilities through 3D printing. My first approach was to print a full hashtag-shaped structure and test how the individual parts could interlock. However, this method proved unworkable. The curved edges and oversized dimensions made it difficult to connect the pieces without using glue, which compromised structural integrity. These challenges led me to further refine both material choices and fabrication methods to better realize the intended form and function of the armor.
For this iteration, a 16×16 structure was 3D printed; however, the scale was adjusted too small. Most of the interlocking elements fused together during the printing process, making it impossible to separate them or use the chainmail structure as intended.
Building on the insights gained from the previous attempt, I revised my approach for the next round of printing. Using Rhino, I deconstructed the original 16×16 model and isolated a core unit consisting of four interlocked elements. This structure was then scaled up and reprinted as a 4×4 configuration. The increased scale allowed for clearer observation of the structural details. The next phase involved refining the form by strategically adding or removing components within a defined framework, gradually evolving the shape to more closely resemble the hashtag symbol.
The successful outcome of the model led to a new phase of structural refinement. I began focusing on modifying the form to better reflect the appearance of a hashtag. The previous design featured a square divided into four interlinked sections, connected through the negative spaces of four smaller squares. To improve clarity and precision, I recreated the model using a 1×1 planar layout, allowing for a more accurate representation of both the top and side views. This step provided a clearer framework for future structural adjustments.
Based on the success of the last version, I have new ideas for modifications. In the last structure, all the structures were of the same thickness. To make the #'s stand out, I made the shape of the #'s in the centre of the structure thicker and the four squares that are intricately connected around the perimeter thinner. Afterwards, it was printed to see the results.