Modeling Lighting & Rendering Class Assignments

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This outdoor scene was my final project for Modeling Lighting & Rendering 1 in Fall 2015. Just about all of the materials in this frame were added by hand, and most of the textures were made for the scene using procedural materials methods.

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This frog with a Modeling Lighting & Rendering 2 assignment. We were tasked with taking a UV Mapped 3D Mesh and painting it in 3D Coat, exporting an AO map, Normal Map, Displacement Map, and Color Map. These maps were then mapped to a .obj file in C4D where I rendered the frog in a studio lighting setup.

CanSat – Nasa sponsored project in collaboration with U. Brideport Grad Students

In July of 2014, I was contacted by a group of graduate students from the University of Bridgeport. They were participating in a competition sponsored by NASA called CANSAT. In CANSAT, teams are challenged to design and manufacturing a satellite to ultimately be tested a launch site in Abilene, Texas.

The students reached out to me, as far as I could tell, because they were so busy with their coursework. When their semester finally ended and they had time to finally start building, the University closed down the machine shop for the summer. They messaged the 3D Printing Club’s facebook page and after a brief conversation with the team leader, I invited the group to come to my home machine shop in Greenwich, CT. At the time the garage was very well furnished with all sorts of tools and I welcomed the grad students to use them. I was surprised that they had made it so far through academia without developing a knack for power tools, so I had to intervene a lot!

Because of myself and the 3D printer I utilized for printing their parts short notice, I was able to rapidly iterate and accelerate their design process. Based off my experience with 3D printers and FDM printed parts, I successfully educated the engineering team towards what they needed to do to increase the manufacturability/printability of their design without sacrificing strength.

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X-Carve CNC Router

Okay, so I caved. The previous CNC machine was sold to pay for a new Macbook back in 2014, and it was collecting dust for a while so I didn’t feel too bad about getting rid of it… I saw the need to get a new router when I started brainstorming for my Full Body 3D Scanner V2…. I wanted to cut the huge pieces that were over 2′ in either direction on this new router.

I eventually decided to pre-order an X-Carve kit, and assembled it over a few weeks with my girlfriend! It works very well, my only gripe is that the GRBL firmware it runs off isn’t exactly real-time. G-code is streamed to the controller through a local server on my computer that relays g-code generated from the X-carve website. It’s very complicated to make this router 3D carve, but Mastercam should be able to create g-code for it!

Anyway, here it is!
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UConn 3D Printing Club

In 2013, I helped found the University of Connecticut’s first 3D Printing Club. With my executive board we created a place for students to collaborate on creative design and engineering solutions. This is a club that is open to all members of the university community, not just engineers, and embraces all aspects of the 3D printing community, both functional and artistic. The club meets at least once a week and host design competitions, plan outreach events, and discuss advances in the technology.

Here’s the club facilities, located within a Material Science Lab on the second floor of the Engineering 2 building.

Here’s a feature video the University made about me and 3DPC in 2015, for their YouTube Channel.

This photo was taken Mid-2014 I believe, this was back when the Club only had one single printer – a bulletproof MakerGear M2 that we’ve since put tens of thousands of hours on!
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This was the first meeting of Fall 2014
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During the first meeting of Spring 2015, members were challenged to create the tallest spaghetti tower possible, using only 20 strands of spaghetti. The final tower had to withstand a load 4 marshmallows at the very top of the structure!
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A young boy staring at an in-progress print during a KUBE program we collaborated on, sponsored by the Asian American Cultural Center.
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Excited prospective engineering students from surrounding CT high schools eying a Makerbot Replicator 2 3D Printer as it prints a bust of me, during the UConn School of Engineering’s event ‘Exploring Engineering.’
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Full Body 3D Scanner V2 Mockup Renders

Having finished my first 3D Scanning Machine , I wanted to try to make another. It’s still a huge WIP, but this time the goal is to have it 100% 3D modeled down to every nut and bolt before I go off and build it. So far the proof of concept renders are fantastic and this is a project I’m looking forward to finishing at some point.
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Homemade 3D Body Scanner

In July 2014, I was commissioned by a company called Comradity from Stamford, CT, to create a device that would allow for individuals to be 3D imaged so that they could create figurines of people with a 3D printer. By the end of this project, I worked with Comradity to develop a marketing video that demonstrated the potential of the machine my partner and I created. The aim of this video was to introduce potential business partners to the capabilities of this technology, so that individuals could realize potential markets to venture into with Comradity.

Here is the video we came up with! Comradity was really happy with it- so I was thrilled, but if you ask me I do not think I come off as the most enthusiastic person in front of a camera…

Rewinding a year back a year to the start of my build-log of the design, manufacturing, and testing processes that we essential for the proper functionality of such a technical device!

To get started I made a mockup of the pedestal base in SolidWorks, this way I could figure out what problems I would have before anything was physically made thus saving time and money. An added bonus was that once I figured out the components I would need from McMasterCarr, like bearings or motors, they had.sldprt files available for download that I could 3D print. This meant I could further test the fit and performance of pieces, albet while the machine did not bear any major load, before I committed to buying real parts from the company. Furthermore, these models were imported into my SolidWorks assembly, saving me time in the design process.
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After having a solid concept of this product on the computer, I got to work manufacturing parts on a Shopbot CNC Router.
CNC Routing the Scanner Base
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Fast forward to the point where I gave it a simple paint job! There was a good amount of trial and error in picking an appropriate motor that an Arduino could power… I went back and forth on using a stepper motor driver and some 400+ oz motor or just using a DC 115v motor and controlling speed with some sort of dimmer. Eventually we settled on the latter, and eventually the pictures in this log will start showing the DC motor instead of the Stepper Motor. Ultimately this decision came back to the technical feasibility and practicality. Yes, in the future it might be useful to control rotation very very precisely, but for this machine it was way cheaper to not buy a high current stepper driver. An added bonus is that the dimmer that ultimately controlled the DC motor let us fine tune the current sent to the motor, so that no matter the weight of the individual, the platform would still rotate at 3RPM.

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Eventually, because of hand drilled holes and awkwardly making certain things together, the machine’s tolerances became a lot looser. The biggest negative impact from this was that the chain drive I designed would have a nearly constantly changing tension in the chain. At this point in the project I could no longer get access to the Shopbot and I didn’t build my X-Carve CNC Router yet, so parts that were funky needed to be fixed by hand instead of recut. In short, a chain tensioner needed to be created for the scanner! This was made out of various nuts and bolts from around my garage, a spring from a nerf gun piston, and some polyester tubing. Sometimes form follows function from a very far away distance… like a creepy stalker with a 500′ restraining order….

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This is what the finished standing platform looked like! I’m really happy with how I added the skateboard grip tape to the top surface, people saw this texture and realized this platform was something that was built to be stepped on because of it. There was a cover for the DC motor at one point, but it got lost (D’oh!).

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Another part of this scanner was developing a tower to move a Microsoft Kinect up and down to capture the full body of an individual. This was critical, because the Kinect does not have the best field of view, if you had the scanner farther than 25″ from the individual there’s a drastic loss in scan resolution. The mock of of this tower was created with some 20mm aluminum extrusion, some pine lumber, a bit of MDF for the top and base, some I-bolts for pulleys, skateboard bearings, various fasteners, and an awesome 3D printed kinect slide that is featured below.

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This video is a test of the tower with a very basic script on the Arduino UNO that controls the scanner. Component wise, the tower has a A4988 Stepper Motor Driver made by Pololu and a 235oz NEMA 23 Stepper motor I found in a surplus scrap yard! The scanner ended up needed a 2:1 pulley so that the stepper could actually lift it, and this made it super slow. Luckily this low speed ended up being beneficial, because when the Kinect was running and Skanect was capturing a 3D point-cloud it could easily lose tracking of the person if the camera or the platform moved too fast.

Okay so for the next part of this project, I had to focus on making it pretty. To be completely transparent, by this point the project had an approaching deadline so I needed to make something quick. The design considerations I had were basically that the exterior needs to hide the electronics from being damaged or seen, allow fairly straightforward access to the electronics if new firmware needed to be updated. I wanted to hit a sleek aesthetic, and if I were to try to nail that better I would have designed a pattern and vacuum formed a final exterior casing- but shoulda woulda coulda… frankly it didn’t look half bad in the end so check it out!

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All that was left was detailing the rest of the tower to match the base that I had made out of polyester sheeting and MDF, 2 cans of black spray paint did the trick nicely. Here is everything all together, the scanner is fully completed.

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DONE!

Who am I?

Me
My name is Lucian Chapar and ever since I was old enough to be trusted not to eat Legos, I have always been building, designing, and creating.

I gradually went from Legos to Erector sets, and sought the need to make my own parts time after time. I now find myself with blank sheets of polycarbonate and blocks of 6061 aluminum, having designs and ideas I set out to build in the machine shop of a garage I have assembled.

Since graduating high school I have continued to gain experience with CNC machines, as well as purchasing a FDM 3D Printer. Additive manufacturing has opened so many pathways and doors I want to follow, leading straight to the core principles and understandings of design and prototyping.

I encourage you to browse this website via the categories. I have meticulously kept archives and build-logs of many of my projects over the years, in order to have a presentable display of my accomplishments.

    Let the future tell the truth, and evaluate each one according to his work and accomplishments. The present is theirs; the future, for which I have really worked, is mine. ~ Nikola Tesla

What is UnhappySk8?


Unhappy Sk8, or Unhappy Skate as it’s sometimes called, is a longboard brand started by myself and my good friend Kohei Urakami. The brand started when I had ripped my Loaded Slide gloves in a fall and knew I could make something better.

Founded October of 2011, we planted our roots in the heart of social networking: Facebook. We also quickly put up a corresponding Youtube channel. I even tied all of it together with a website to match.

My personal premise for the brand was to take the things I built for myself and my friends, and get them available to a wider audience. I thought it would be cool to have a business model that allowed me to acquire more funds to get into the realms of more and more advance creations. At our start, we would throw around the idea of doing an entirely aluminum board or a Carbon Fiber composite board with a foam core; but the shear materials alone were out of our grasp. I still have that intent and drive to take Unhappy Sk8 to the next tier, but we’re still striving to get there.

Why Nerf?

Over the past 8 years now, a huge hobby of mine has always been modifying toy nerf blasters.

The interest came from a desire for something safer than Airsoft- I didn’t want to be the next person to have a tooth shot out. And I wanted to find something cheaper than Paintball- I didn’t have the funds to pay $100 for a couple hours worth of paintballs every time I wanted to play.

I knew there had to be some alternative. Fast-forward to May of 2008 and I found myself watching Zack Scott’s Easy Nerf Gun Hack video on Youtube. I had to try it, and so I did. The immediate improvements from overriding and removing basic safety features excited me. I had a boundary I had a passion to push, and so I did.

With projects I had in mind for flinging foam darts to unheard distances, the tools I surrounded myself with quickly became inadequate. My handy Dremel 4000 and Ryobi drill no longer cut it. That Christmas, I got a 16″ Craftmen Scroll Saw to take a shot at Nerfhaven.com user Captainslug’s design called the +Bow. I had decent luck with it, but I knew with more tools I’d trade limits for potential.

Now 2009, the online community was rebarreling multi-barreled turrets, and selling spacers to hold the Polyester tubing in place to make our blasters more accurate. I wanted in, and need a drill press suddenly. I had this blaster called the Rapid Fire 20, and after replacing the barrels I took my shinny new drill press went to town on a 1/8th thick piece of red polycarbonate.

Now August of 2010, next think I know, I needed a CNC router to work at a level of precision I wasn’t capable of. The year after, a 1951 Van-Norman Milling Machine. This Christmas, I got a Make Replicator 2 3D printer.

I can now create anything I’m capable of designing. Nerf as a hobby continuously pushed me along, demanding more and more skill-sets and equipment as I went. That is why I played with nerf guns.

Me, circa 2012, participating at a nerfing event with a homemade blaster built out PVC and other off the shelf hardware.
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