2 inches of exterior polyiso insulation, continuous air and water barrier, standing seam roofing, cedar T&G + 26ga steel siding, and about 3,876 lessons learned 😅

Goals

Take a stack of exhibit ideas dreamt up by the Education staff, and turn them into an exhibit in one year, on a tight budget.  The exhibit must be movable so that the exhibit hall can be used for large rental events.

Results

Science & Main is one of the most popular exhibits at the Museum, and was achieved at a fraction of the cost of most other exhibits in the museum.  See the captioned photos below for details and process photos…

The Explora-inspired marble wall is adapted for MSC's needs: large plastic balls instead of marbles, and more durable components.

A photo of the marble wall shortly after opening. I added rubber edge-protectors and replaced the wooden pegs with plastic.

The bicycle gearing activity allowing visitors to compare the differences in gear ratios.

Instructions for the paper airplane launcher

We prototyped and tested the paper airplane launcher to determine the best layout for the paper airplane activity.

A view of the airport control tower with launchers in the background

The 'Food fight' catapult. The device is quite precise: if you determine the correct variable to hit a given target, you will hit it reliably with those variables.

Some visitor creations

More visitor creations

A view of the bike gearing activity and the bike shop facade.

Initial concept rendering

Revised concept rendering, after construction methods and components were refined, Science & Main.

Styling detail, which informed the construction methods.

Logos, desiged by intern Qian Zeng

Setting up the facades with the help of a budget-friendly gantry crane. The yellow scaffolding was later used as part of the backdrop of the construction site.

Oops, sorry George...

Guts of the paper airplane launcher

The marble wall pieces were built using this setup. A pin-router attachment was used for the curved pieces.

Cole demonstrating some of the high-tech tools we used

It turns out handwheels with revolving handles are not MSC-kid-proof, so we added keyways to fixed-handle handwheels. In this photo: enlarging the bore with a boring bar.

Adding a keyway with the lathe, since we did not have an arbor press.

We initially used an off-the-shelf pulley as the drive wheel in the paper airplane launcher, but it was quickly shredded. In this photo, machining a new wheel, which held up well.

Sub-Projects

View these projects in more detail:

Drop Tower
Pipe Organ

The Drop Tower enables visitors to repeatably drop a racquetball 20 feet onto an angled surface. The angle and material of the surface can be changed, enabling users to experiment with the 2 variables and discover how they affect the trajectory and bounce height of the ball. The targets provide a goal for visitors to aim for, though many simply experiment on their own.

Process

We built and tested several prototypes to determine whether or not our plans were visitor-friendly, the reliability of the ‘dropper’ mechanism, and the feasibility of the chain conveyor.  See images below for more details…

Challenges

• Reliability was a serious concern since some of the working parts are 20 feet in the air, and difficult to access.
• The height of the design was difficult since the museum lacks an appropriate lift or convenient ceiling lift points.  The shop ceiling is not much over 8 feet, and the freight elevator is very small, so the components were built in sub-assemblies, test-fit and finished in the shop, and fully assembled on the exhibit floor

Design Details

• Gear reduction and a rotary damper prevents visitors from spinning the Prism in an uncontrolled fashion
• Controls for steps 1,2, and 3 (Load, Adjust, Drop) are arranged in sequential order for intuitive operation
• An angle indicator makes the experiment replicable

Detail of bounce-height scale

Detail of prism rotation indicator

Detail of top module and electrical boxes

Detail of user controls

Our first prototype was designed to test some of the mechanical elements, and see how visitors would interact with the component. We found that having 3 different ball types was too much for most visitors, so we eliminated the wiffel ball and golf ball, and kept the racquetball.

Testing to determine the trajectory of dropped balls

2nd prototype to determine reliability of top module mechanism. The testing revealed some reliability issues that we were able to solve before the Drop Tower was installed.

Testing the 2nd prototype at full height to determine how the chain would act. Thankfully, we found no problems!

I completed the final Overall design in Rhino at the same time Cole was completing the Top Module design in Solidworks. I then combined our designs and completed final construction drawings in Solidworks.

Fabrication in the shop

We had to set up during off-hours, since the museum was open 7 days a week

Karl helping with final electrical hookups before final assembly

Construction Drawings

Below are examples of construction drawings I created with Solidworks.  They were given to a commercial welding company, who fabricated and delivered the pieces.

Goal

Build a kid-proof pipe organ with exposed inner workings.  As far as I know, this is the only pipe organ in the world that is available for public use.

Design Details

• Kid-proof keyboard with 1-piece plastic keys
• ‘Drop the bass’ button for the big zinc pipe
• All mechanisms visible

Detail of the pipes, donated by David Storey

The moving valves are visible from the player's perspective as she presses the keys

Detail of regulator, blower, and electronics

Detail of kid-proof keyboard

Illustrator rendering of the design, before I handed design and fabrication responsibilities to Cole.