05/28/2015 – Eric Gundersen
Balance, patience, and plenty of coffee are indispensable when it comes to constructing a 16’ x 16’ city out of cardboard in about 16 hours. That is the mission before us at the second annual Denver Mini Maker Faire (coming up on June 13 and 14). Eight of us gathered on a cold and rainy day in May for our first preparation/prototyping session and learned much during those four swift hours.
Lesson #1: Safety, safety, safety
Two finger tips were lost in the first 30 minutes – fortunately they only belonged to a glove while the hand inside was left unscathed. Cardboard is dense and even with sharp knives it requires a fair amount of strength to cut. Always keep your blade sharp. If cutting becomes a challenge dispose of the blade properly and replace it with a fresh one. Retract your blade or store safely between cutting sessions. I had a friend who required multiple stitches after stepping on an X-Acto blade stored in a coffee mug, blade up, on the ground.
We used hot glue to affix cardboard to cardboard which takes time to set. The glue can get up to 380⁰ F. Instead of risking burns use binder clips to hold your pieces as they cool. Also, remember to unplug your glue gun immediately after use.
Lesson #2: Cutting
A straight edge or L-square is beneficial for making long cuts. Make two passes on the cut so you don’t have to use as much pressure. To make a clean corner for a fold, score the interior of your piece by making a shallow, straight cut.
Lesson #3: Creature Comforts
Working on your hands and knees can get uncomfortable. Consider using knee pads or gardening kneeling pads. Coffee also hits the spot.
Lesson #4: Balance
Our team is fairly diverse with a variety of skillsets. Some of us are more technical and some more artistic and everyone has strengths & weaknesses. We organically broke up into three smaller groups to tackle infrastructure (base plates), landmark pieces (a skyscraper and suspension bridge), and “greebling”/”gingerbread” details in parallel.
It… was… sloooow. After four hours (nearly 25% of our allotted time) we had:
- 8 houses
- 1 swing set w/ slide
- 5 trees
- 1 classy above ground swimming pool
- 2 base plate platforms
- 1 skyscraper w/ water tower
- 1 bridge that took 10 minutes to make
- ½ a bridge that took 2 hours to make
We learned that a bargain must be struck between quality and speed. Work too fast and it looks like junk, while painstakingly obsessing over getting all the details right takes way too long.
As we made ready to leave and looked across all the modest structures we realized that it’s the city that we’re making; not the house or tree or skyscraper. The flaws are absorbed by the scope, variety and whimsy of the landscape. These pieces make up the whole just as your companions’ participation make up the experience.
We’re going to create an assembly line process to accelerate building the building of 144 houses, our goal. We’re going to separate into groups for mass production (speed) and unique landmark pieces (quality). Perhaps you’ll visit us at the Denver Mini Maker Faire on June 13th & 14th, or better yet roll up your sleeves and give us a hand.
If one day you find yourself building a city out of cardboard remember to be creative, be patient, encourage your partners and have fun!
Editor’s Note: See the Cardboard City, and many other curiosities (you can even build your own cardboard creation), at the Denver Mini Maker Faire on Saturday June 13 and Sunday June 14 at the Denver Museum of Nature and Science. Join MakerBoulder and Level(3) in some maker magic!