METHOD OF THREE-DIMENSIONAL THEMING
A method of fabricating a thematic design article is disclosed. One of the embodiments of the method comprises the step of formulating from a three-dimensional computer model of an article, design parameters for panel elements of the article. The method further comprises the step of controlling a wire bending device responsive to the design parameters to form the panel elements, wherein the panel elements are comprised of horizontal and vertical sub-elements comprising continuous sub-panels, linear cut to form sub-panels, or a combination thereof.
This application claims the benefit of provisional patent application U.S. Ser. No. 60/985,093, filed Nov. 2, 2007, which is expressly incorporated herein by reference.
BACKGROUNDTheming generally comprises the design and creation of three-dimensional structures for use in entertainment, parade, decoration, advertising, architecture and other artificial scenery applications. In one application, theming is used extensively in theme parks for the creation of realistic natural and fantasy scenery, as well as in television and motion pictures to create the illusion of realistic, or fantastic, scenery. Theming may further be utilized, for example, to create a scaled-down mountain scene as a part of a log flume ride at a theme park, providing the customer with the simulated experience of a ride through mountain country. Specifically, theming may be used to create realistic rock work to form a mountain or other natural scenes without having to use actual boulders or unwieldy and expensive rocks. Furthermore, the substantially hollow structures created by theming allow concealment of machinery, cables, and other infrastructure.
Theming is accomplished in four primary phases. First, in the design phase, the size, shape and relative dimensions of primary and secondary structures are determined. Second, in the planning phase, material requirements are assessed and analyzed, the project is dissected into areas, zones, scenes, elevations, and order of assembly is determined. Third, in the fabrication phase, the latticework for primary and secondary structures is assembled. Finally, in the field fabrication phase, steel construction is accomplished, cement and other surface preparation is done to the latticework, and painting and other artistic decoration is done.
Traditionally, theming of three-dimensional elements is accomplished through the creation of a three-dimensional lattice or skeleton, upon which a formable matrix material may be applied and painted or otherwise decorated to achieve a desired appearance. Typically, the three-dimensional latticework will consist of wire lattice manually bent into specific geometric shapes. The manual techniques described can only approximate the wire geometries of angles, lengths and contortions. Furthermore, these techniques can be very labor intensive, time consuming, inaccurate and expensive.
Furthermore, existing manual techniques can be limited in that they limit the ability to effectively scale up or otherwise reproduce existing models without subjectivity. Essentially, the creation of the necessary three-dimensional structures is more art tan science.
It is therefore desirable to provide a new process to efficiently realize three-dimensional theming using scalable, digital information that may be translated into various digital formats. This digital information may be captured from sketches, photographs, three-dimensional models, and other suitable means. It is also desirable to provide a process for incremental design and assembly of artificial thematic elements.
SUMMARYThe present invention provides a method of fabricating a thematic design article.
A method in accordance with the invention includes the step of formulating, from a three-dimensional computer model of the article, design parameters for panel elements of the article. Panel elements may be defined as rectilinear or organic shapes comprised of horizontal and vertical bent wire components that integrate together to form a thematic article or design element. These panels can be designed in various dimensions but will always be a representation of the digitally created thematic article or design element. These design elements may include, for example, dimensions of the panel elements and the size and material composition of the components of the panel element (e.g., the gauge and composition of wire). The method further includes the step of controlling a wire bending device responsive to the design parameters to form a panelized element. In one embodiment of the invention, this step includes the sub-steps of bending a first continuous wire to form a horizontal panel sub-element, bending a second continuous wire to form a vertical panel sub-element and joining the horizontal and vertical panel sub-elements to form the first panel element. A second embodiment of the invention illustrates individual horizontal, vertical, and auxiliary bent wire lengths that integrate accordingly to form a single panel of an element.
In another embodiment of the invention, there is provided a method of fabricating a thematic design article, comprising the steps of: formulating from a three-dimensional computer model of the article, design parameters for panel elements of the article; and, controlling a wire bending device responsive to the design parameters to form the panel elements, wherein the panel elements are comprised of horizontal and vertical sub-elements selected from the group consisting of continuous sub-panels, linear cut to form sub-panels, and a combination thereof.
In another embodiment of the invention, there is provided a method of fabricating a thematic design article comprising the steps of: formulating from a computer model parameters of a three-dimensional article, wherein the parameters comprise horizontal, vertical, and otherwise intersecting elements of a surface; creating an instruction set from the parameters and intersecting elements of a three-dimensional representation of the three-dimensional article whereby a computer numerical controlled wire bending apparatus forms the intersecting elements; integrating the intersecting elements to form a panel section; assembling a multitude of similarly fabricated panel sections to form an accurate shape of the three dimensional article; and, processing the panel sections and applying a matrix material to the assembled panel sections.
The inventive method overcomes the drawbacks and deficiencies of the aforementioned theming techniques by providing a process for design and assembly of artificial thematic elements. Specifically, the invention discloses a novel method by which one may create a three-dimensional support structure faux theming that is accurate, scalable and highly reproducible with substantially decreased manufacturing and assembly costs.
The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the disclosure or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
The disclosure can be better understood with reference to the following detailed description taken in conjunction with the accompanying drawings which illustrate preferred and exemplary embodiments, but which are not necessarily drawn to scale, wherein:
While the invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, preferred embodiments of the invention with the understanding that the disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the illustrated embodiments.
Referring now to
The inventive method may continue with step 40 of formulating, from the three-dimensional computer model of the thematic design article, design parameters for panel elements of the article. Step 40 may include, for example, sub-step 42 of volume study for determining a volume or space of the thematic design article. Step 40 may further include sub-step 44 of material requirements for identifying material requirements for various components of the panel elements including, for example, the gauge of wire used in forming the panel elements and the material composition of the wire which may be determined, in part, in response to the volume of the article and anticipated loading. The gauge of wire used in forming the panel elements is preferably from about 6.35 mm (millimeters) to about 12 mm in diameter. However, other suitable gauges may be used. Preferably, the wire may be made of materials such as stainless steel, mild steel with zinc coating, metal, or other suitable materials. Step 40 may further include sub-step 46 of panelization design process. Step 40 may further include sub-step 48 of identifying primary structure or structural requirements 50 and identifying secondary structure or structural requirements 52. Structural requirements may be determined by environment, structural codes, local regulations, seismic conditions, wind load conditions, or other structural requirements. Referring to
The method 10 may further include step 64 of controlling a wire bending device responsive to the design parameters to form the various panel elements. The wire bending device may comprise any suitable wire bending device. For example, the AIM Wire Bender wire bending device from Automated Industrial Machinery of Addison, Ill. may be used. The design parameters for the panel elements may be translated into coded commands for a computer numerical controlled (“CNC”) multi-axis wire bending device, which can then form each individual panel element or section. Final assembly of the pre-fabricated panel elements or sections is therefore substantially less labor intensive than manually building the desired article from scratch, with the added benefit of heretofore un-achievable design faithfulness and reproducibility.
Referring now to
Referring now to
In one of the embodiments of the method, there is provided a method of fabricating a thematic design article. The method comprises the step of formulating from a three-dimensional computer model of the article, design parameters for panel elements of the article. The formulating step may include the sub-step of identifying a gauge for a wire. The formulating step may further include the sub-step of identifying a material composition for a wire. The formulating step may further include the sub-step of determining a volume of the article. The method may further comprise the step of controlling a wire bending device responsive to the design parameters to form the panel elements. The panel elements may be comprised of horizontal and vertical sub-elements comprising continuous sub-panels, linear cut to form sub-panels, or a combination thereof. The controlling step may include the sub-steps of bending a first continuous wire to form a horizontal panel sub-element, bending a second continuous wire to form a vertical panel sub-element, and joining the horizontal and vertical panel sub-elements to form the panel element. The controlling step may further include the sub-steps of bending linear, cut to form wire to form a horizontal panel sub-element, bending linear, cut to form wire to form a vertical panel sub-element, and joining the horizontal and vertical panel sub-elements to form the panel element. The method may further comprise the step of assembling a plurality of the panel elements into a first panel section. The method may further comprise the step of connecting the first panel section to a second panel section. The method may further comprise the step of assembling a plurality of the panel elements into a first panel section of horizontally bent wire. The method may further comprise the step of assembling a plurality of the panel elements into a second panel section of vertically bent wire. The method may further comprise the step of applying a matrix material to the first panel section and to other panel sections. The method may further comprise the step of applying paint or other design elements to the first panel section and to other panel sections.
The final thematic design articles that may be formed by the embodiments of the method of the invention may include boats, trees, roots, buildings, caves, mountains7 rocks, waterfalls, pools, ponds, rivers, streams, characters, free form sculptures, nature scenery, and other suitable design articles.
A method in accordance with the invention represents a significant improvement over conventional methods for forming thematic design articles. The inventive method is less labor intensive than prior methods that require manual formation of the wire grid for the article. The method is also much more precise in recreating the article as designed. The methodology is accurate, scalable and highly reproducible leading to improved designs at a lower cost.
Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. The embodiments described herein are meant to be illustrative and are not intended to be limiting. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims
1. A method of fabricating a thematic design article, comprising the steps of:
- formulating from a three-dimensional computer model of the article, design parameters for panel elements of the article; and,
- controlling a wire bending device responsive to the design parameters to form the panel elements, wherein the panel elements are comprised of horizontal and vertical sub-elements selected from the group consisting of continuous sub-panels, linear cut to form sub-panels, and a combination thereof.
2. The method of claim 1, further comprising the step of assembling a plurality of the panel elements into a first panel section.
3. The method of claim 2, further comprising the step of connecting the first panel section to a second panel section.
4. The method of claim 1, further comprising the step of assembling a plurality of the panel elements into a first panel section of horizontally bent wire.
5. The method of claim 1, further comprising the step of assembling a plurality of the panel elements into a second panel section of vertically bent wire.
6. The method of claim 2, further comprising the step of applying a matrix material to the first panel section.
7. The method of claim 1 wherein the formulating step includes the sub-step of identifying a gauge for a wire.
8. The method of claim 1 wherein the formulating step includes the sub-step of identifying a material composition for a wire.
9. The method of claim 1 wherein the formulating step includes the sub-step of determining a volume of the article.
10. The method of claim 1 wherein the controlling step includes the following sub-steps:
- bending a first continuous wire to form a horizontal panel sub-element;
- bending a second continuous wire to form a vertical panel sub-element; and,
- joining the horizontal and vertical panel sub-elements to form the panel element.
11. The method of claim 1 wherein the controlling step includes the following sub-steps:
- bending linear, cut to form wire to form a horizontal panel sub-element;
- bending linear, cut to form wire to form a vertical panel sub-element; and,
- joining the horizontal and vertical panel sub-elements to form the panel element.
12. A method of fabricating a thematic design article comprising the steps of:
- formulating from a computer model parameters of a three-dimensional article, wherein the parameters comprise horizontal, vertical, and otherwise intersecting elements of a surface;
- creating an instruction set from the parameters and intersecting elements of a three-dimensional representation of the three-dimensional article, whereby a computer numerical controlled wire bending apparatus forms the intersecting elements;
- integrating the intersecting elements to form a panel section;
- assembling a multitude of similarly fabricated panel sections to form an accurate shape of the three dimensional article; and,
- processing the panel sections and applying a matrix material to the assembled panel sections.
13. The method of claim 12 wherein the computer model is a CAD (computer-aided design) model.
14. The method of claim 12 wherein the intersecting elements are wires.
15. The method of claim 12 wherein the matrix material is a polymeric material selected from the group consisting of polyvinylchloride and polyethylene.
16. The method of claim 12 wherein the intersecting elements are formed by the wire bending process in a continuous manner.
17. The method of claim 12 wherein the intersecting elements are formed by the wire bending process in a non-continuous manner.
18. The method of claim 12 further comprising the step of applying paint and design elements to the assembled panel sections.
19. A thematic design article formed from the method of claim 1.
20. The thematic design article of claim 19 comprising a boat, tree, root, building, cave, mountain, rock, waterfall, pool, pond, river, stream, character, free form sculpture, or nature scenery.
Type: Application
Filed: Nov 3, 2008
Publication Date: May 7, 2009
Applicant: Scenario Design, Inc. (Los Angeles, CA)
Inventors: Paul Buckley (Oak Park, CA), Anthony L. Caruso (Northridge, CA), Sanford D. Damasco (Irvine, CA), Paolo Hilario (Walnut, CA), Paul Nylander (Laguna Nigel, CA), Gerry Rey (Buena Park, CA), Tom Stapleton (San Pedro, CA), Ryan Trinidad (Los Angeles, CA)
Application Number: 12/264,156
International Classification: B21F 45/00 (20060101); B21C 51/00 (20060101);