Sam Dirani

Cocoon: Sponsored by a textile manufacturer and working as the designer with a talented team of textile engineers, marketers, and business professionals, we developed a high performance Wheelchair Blanket. The result is a blanket designed to contour around a person seated in a wheel chair. Made from a breathable 4-way stretch thermal textile(gray fabric above) and a 2-way stretch warp-knit quilted textile interlaced with a conductive fiber(orange fabric above). The contouring preventing it from being caught in the wheels or slipping off as well as helping to regulate body temperature. The controller incorporates a simple user interface comprised of raised rubber outlines and LED lights. The controller allows the user to adjust the temperature and deciding which specific lower body zones they want to heat, including the option to cycle through the selected heated zones. The controller also houses the batteries that provide the power source for the heated blanket.

DDLAMP-Acrylic and Spandex - A fabric corded accessory lamp made completely from acrylic including the lamp shade frame. The lampshade was made from a custom pattern and is fixed to the shade using a hidden gasket method that allows it to be removed for cleaning or changing color.
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Window.2011- Mixed Media.fiberboard,textured paint - Experimentation using enamel and textured paints to build up a surface and then masking that surface to create layers of depth. All seen though a limited perspective--a window.
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Medical Soft goods Prototype - A challenging soft-goods prototype I created for a local design firm. Working only from sketches, I created initial patterns by draping over a model, fine tuning the pattern, added seam allowances and finally producing the finished prototype out of foam and high performance textiles.
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AtomRed Cloak Design - Inspired by the cloaks popularized in the 1800's and the clean minimal lines of Asian fashion, this caped cloak bring to life my desire to modernize and bring the cloak back into the modern fold of fashion. The cloak is made from a 2-way stretch warp-knit fabric made locally in NC. The red accent fabric is made from a crushed faux silk. The cloak has a removable center panel held in by metal snaps, and the entire garment is reversible.

AtomRed Cloak Design2 - Patterns were developed through a combination of draping and existing pattern manipulation to create a modern form fitting garment. All components were hand-cut and sewn together. I proudly wore the completed cloak to my graduation, as a substitute to the traditional gown.
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HIDDEN SCRIPTS- In this polished acrylic piece, I wanted to recreate a moment we have all had. The second-look, the "double-take" when you look back because you "thought you saw something." As the light changes around this 3-dimensional dynamic piece, it catches the unpolished edges of the acrylic constantly changing the perspective for the viewer. Resulting in an ever changing illusion of familiar words or scripts showing through.
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Student work - a Watch modeled and developed by my student and I over a week of one-on-one tutorial sessions in Rhino 3D Cad software.
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Aeon-metal and glass1 - Inspired by a found glass object, I envisioned an ancient relic, drifting through the vacuum of space dulled by the elemental exposure, of eons.

Aeon-metal and glass2 - Made from steel and glass with internal circuitry, the outer pyramidal shell is hand cut from steel and welded before receiving a surface polish and an aged treatment. The resulting texture invites the observer to touch the object and become a participant. Internal circuitry is activated, upon touch, that turn on hidden lights bringing the object to life. The entire sculpture is mounted via ball bearing to a stationary base, adding a level of unexpected movement as the surface is explored.

Super Boots Redesign - These sketches explore the redesign of updated modern Superhero boots. These redesigns incorporate a flexible inner sock sheathed in a semi-rigid outer shell.

Oak Chair - A chair made from hand cut and shaped laminated and solid oak sections along with an aluminum spine. The chair hugs the human form and invites the participant to not only admire the chair when seated but from afar as well.

chandelier-acrylic and fabric - An organic form sculpted within 3D space and fabricated from two-dimensional materials using modern CNC equipment. Currently experimenting with various textiles to create a "skin" that will envelope the lower plastic form. Once a textile is selected, a pattern will be created using the original 3D Rhino model and fine-tuned according to the properties of the textile.
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Wolverine-Costume - Recreating a comic character isn't easy. I've been a fan for years and since Hollywood reintroduced him to the world, I've been wanting to challenge myself and attempt to recreate the costume. Inspired by an iconic image of "Wolverine", the various components where researched and broken down. Then recreated using 3D software, a laser cutter, acrylic, leather, wood,metal and paint. Combined with a little beard growth and hair gel, we end up with a fairly successful recreation of the character.
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Texture Study-acrylic - Experimenting with the effects of lighting on various shapes as well as the recreation of fabric texture onto acrylic.

Habitat for Humanity portable display Ideation 1: I had the opportunity to think outside the box in order to build a transforming portable box exhibit for the Raleigh Habitat for Humanity Reuse center. It was an opportunity to showcase the ever changing variety offered by the Reuse center, and I enjoyed the challenge of building it completely out of material from the Reuse center.

Habitat for Humanity portable display Final 2: The completed Habitat for Humanity Reuse Center display, Shown here on display at the Raleigh Ideal Home and Garden Show . The Reuse center was short on materials so I had to adapt, making a smaller, more compact display to showcase a sampling of their building material inventory.

Superman-Costume and Boots - While the entire costume is hand-made, the main focus is on the third generation of Super Boots used in conjunction with the costume. Building off an existing rubber sole, Layers of varying lengths of red duct tape were used to create a hollow flexible form. Red rubberized paint was then sprayed onto the entire surface merging the layers of duct tape into a field of red alien textures unlike any other textiles easily recognizable as man-made.
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Lighting study-acrylic and rice paper1 - Inspired by a variety of sea creatures, I wanted to create my own organic form/deep sea monster. two-dimensional materials were used to create three-dimensional structures using Rhino. The parts were cut and hand-formed. Combining LEDs, acrylic, and rice paper completed the creation and helped bring my monster to life. The entire sculpture is hung using a fine steel filament that also serves as a way to deliver power to the internal lighting.

Lighting study-acrylic and rice paper2 - Inspired by a variety of sea creatures, I wanted to create my own organic form/deep sea monster. two-dimensional materials were used to create three-dimensional structures. The parts were cut and hand-formed. Combining LEDs, acrylic, and rice paper completed the creation and helped bring my monster to life. The entire sculpture is hung using a fine steel filament that also serves as a way to deliver power to the internal lighting.

Human Torch-Costume - This project was Inspired by the comic hero, The Human Torch, and a challenge to create the simplest costume possible without losing the essence of the character. The final result is a 4-way stretch Lycra spandex body suit placed over a male form and air-brushed with multiple layers using a collection of custom cut masks to define the musculature and personify the look of smoldering ember-fire!
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Reflection-material exploration - I was Inspired by sunlight reflecting off ocean ripples, and I wanted to capture and recreate it. Acrylic beads were poured over a metal form and slowly heated & cooled over a 24hr period to ensure a proper bond between the beads. The acrylic form was then attached to a laser-cut bracket using an experimentally determined distance to allow for maximum spread of the embedded LEDs. This highlights the surface transitions, ranging from 0.5in to delicate edges of one bead thick.

No Arches Here-acrylic and fabric - This multi-layer permanent installation is a study of depth. The participant is invited to peer through and explore the multiple layers, down to the glowing green metallic fabric base layer, only to realize their own reflection is being cast onto the onyx black front layer, bringing their attention back to the surface where the arches disappear and you are only left with a continuous form partially reflecting the participant and making them an integral layer in this study of depth.
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Artifact Light Ideation 1: I gave myself a scenario. What would I create if given the opportunity to design a movie prop for one of my favorite Characters, Superman. I set about exploring the mythology of the character, and developing a piece of technology that could seamlessly fit into the Superman Mythology. A device powered by the crystals used in the Superman movies.

Artifact Light Ideation 2: After many subtle iterations, I decided on a design direction for my functional movie prop and began building the CAD files that would eventually guide a CNC machine to produce the components out of solid aluminum.

Artifact Light Fabrication 3: Experimenting with CNC fabrication and using more cost-efficient materials such as cardboard, acrylic and foam allowed me to address some tolerance issues before cutting the final aluminum components. The custom internal mechanisms were also designed with the aid of CAD software, parts cut using a laser cutter and hand-assembled with a custom-built LED array.

Artifact Light Final 4: The finished movie prop. Textures and facets help lend an other-worldly feel to this functional piece of technology. Operated by a weight sensitive spring switch, a hidden array of LEDs glow upon insertion of a hand-made crystal into the base. Bringing the Artifact to life, and worthy of the Superman Mythology.

Chaise Lounge Chair: Inspired by the curves of an Orchid, I envisioned this lounge chair being made from fiberglass with a white gel-coating. The Chaise is hollow on the underside and painted with a bright metallic blue, providing a contrast to the orange high-performance fabric covering the therapeutic memory-foam on the surface. To prevent tipping the chair can be secured to the floor using anchors,or discrete cast metal weights can be installed in the underside.

LightUpEducation-Puppet Fabrication - Beginning a few years ago, my partner and I created a company intent on making a difference using the ageless multi-cultural craft of puppetry. We learned on our own and created a variety of characters, hand made costumes, sets and story lines. Becoming the directors, editors and set designers, we funneled our art form into an educational science program that is proving to be a positive factor in the teaching and engagement of young students. We currently have reached over 3,000 students across four states and continue to grow. Our program is completely free and available for everyone to enjoy and use at www.lightupeducation.com
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Exhibit Design: Custom emergency sign: Hidden wall attachment.
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Exhibit Design: Award Base redesign. The original time-consuming base(painted silver) can be seen in the bottom right image along with the original prototype and the final black acrylic and stainless steel design.
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Exhibit design: Custom company history, interactive design
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Package Design Ideation 1

Package Design Ideation 2

Package Design Ideation 3

Century: A custom lighting design inspired by the 18th century. More specifically, the brief time period where steam and electricity first began to coexist. Machines were works of art, complex and constructed of multiple materials and metals by exceptional craftsmen, while the electric wire was often exposed and insulated with paper and cloth. This page focuses on the development of the joint bracket used to stabilize the entire lighting structure. Ideation was done using paper and pencil, the 3D design was drawn in Rhino, most components were made by hand while some were machined using CNC equipment before all parts were tapped, hand polished, and assembled.
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Century: The two main aluminum components designed for this light required holes to be drilled, polishing and multiple bends. I began by using the 3D files to create accurate construction diagrams. And since I did not have access to a metal brake press to form the bends, I designed and constructed a bending jig to form the identical aluminum brackets by hand. The jig was easy to use, and was accurate enough to produce consistent bends without any noticeable discrepancies.
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Century: Initial 3D rendering, Final Assembly and Installation. All the components for the light were polished and assembled. While some of the wiring remains exposed(covered with gold cloth) I did have issues passing wiring through the hollows of the light. After some ideation, experimentation, and research, I was able to develop a wiring/soldering pattern, that allowed all the lights to be wired together and still pass through the small openings in the down-tubes of the light. I also wired a touch circuit directly into the main power line, keeping the design simple without a visible switch. And yes, that is my purple rug.
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Scrubaroo: A team effort to design and develop a cleaning tool addressing repetitive strain injuries in the hospitality industry. For the purpose of fairness and this portfolio presentation, I have tried to focus primarily on the ideation and renderings I brought to the group project.
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Scrubaroo: We began with published statistics and findings from previous health/human factor studies of the hospitality industry. Combining the researched data with surveys and observations we conducted, my team assessed that hospitality related injuries fell into specific semi-related categories. As a result of our findings, we decided to focus on the the largest injury group, the back, and design a solution to alleviate those particular work related injuries.
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Scrubaroo: My ideation contributions to this project ranged from fixed manual cleaning brushes, semi-automated, as well as fully-automated cleaning solutions.
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Scrubaroo: Using anthropomorphic data, along with controlled lab studies to test and determine the proper shape and handle length for our design.
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Scrubaroo: Continuing the testing to determine the proper shape and handle length for our design, using anthropomorphic data, along with controlled lab studies to test for muscle expenditure and fatigue.
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Scrubaroo: Continuing design development using mock-ups to test the proper sponge head shape and an assortment of hinges to maximize cleaning efficiency and usefulness of our design.
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Scrubaroo: Using anthropomorphic data, along with controlled lab studies to test and determine the proper shape and length of the entire cleaning device to minimize strain on key muscle groups.
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Scrubaroo: Design refinement based on all data and observations collected during testing of mock-ups.
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Scrubaroo: Final design solution
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Scrubaroo: Final design solution: Rendering 1
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Scrubaroo: Final design solution: Rendering 2
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Cox Box 1: Working with a design colleague and a group of engineers at ATI (Advanced Rowing Instruments) to design, develop and prototype a new version of the Cox Box--a device used during rowing to time and manage rowing races and performance.
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Cox Box 2: Collected data from field observations, discussions with engineers as well as numerous rowing athletes was analyzed and combined with design inspiration from nature in the form of a small water insect called a Water Boatmen. Known for its paddle-like appendages, the Water Boatmen uses these to row across the surface of the water. The user interface was kept simple and was developed based on the electronic interface desired by the engineers.
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Cox Box 3: The final Design was modeled and fully developed using Rhino3D, and then printed using a 3D ABS plastic printer. The engineering team designed, printed, and programmed custom circuit boards. We assisted in the final assembly as well as painting and thermo-forming an acrylic cover to complete the case. The final design takes advantage of a removable battery pack that allows the user to keep a charged battery pack in reserve at all times.
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Chromecast Ideation: Thoughts and sketches on form and function of the Chromecast. Page 1 of 3
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Chromecast Ideation Rendering: Initial renderings and design for an alternate design direction for the form and function of the Chromecast. Page 2 of 3
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Chromecast Ideation Rendering: Product detail renderings for an alternate design direction for the form and function of the Chromecast. Page 3 of 3
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