Puppet Theater

June -September 2024

In partnership with Chicago’s Cook County Department of Corrections (CCDOC), my team was asked to improve the visitation space at the facility. I co-lead a team in creating a 6-piece, modular puppet theater for children visiting incarcerated loved.

Team: Dalia Diab (co-lead), Taewon Yoon (co-lead), Vicky Laguerre, Deniz Yoruk,

Felipe Macarri, Isabel Pitcher

User Research

Conducted extensive user research to understand the needs of the children visiting the facility, investigating children’s libraries museums, and other educational spaces. Interviewed subject matter experts

Skills: Design Research

Ideation + Sketches

Working around the unique design constraint of not being able to use metal, we brainstormed potential designs, focusing on creating a structure as multi-functional, open, and engaging to children as possible. Taking into consideration safety factors and limited space, we synthesized our designs into a 6-piece modular theater which combines elements of play, sensory, and puppetry.

Skills: Sketching, CAD, Keyshot, Collaboration

Final Design

  • 6-piece modular design

  • Trapezoidal shape allows for multiple orientations

  • 3 modules have negative connection and three modules have a positive hook extrusion to piece together for customizable orientations

  • 5 unique modules

    • 2, Marquis and curtains with matching pull out storage box

    • 1 module with cutout and removable “mini-puppet theater”

    • 3 modules with different games on each face

Rendering of four out of six modules in CCDOC visitation room.

Solidworks CAD Models of modules.

Manufacturing

Rather than limit our ideation by focusing on our constraints, such as limited woodworking equipment and the unique constraint of using no metal, we carefully modified our design to be manufacturable with our resources .

Using finger joints and wooden dowel pins, eliminated the need for screws while adding to the aesthetics of the theater.

I also helped navigate manufacturing challenges by creating custom jigs and angle blocks to clamp the module’s trapezoidal shape together during dry-time, as traditional clamps would not work.

Skills: Problem solving, CNC router, machining, woodworking, painting

Adding finger joints to each panel for metal-free attatchment.

All wood parts cut out on CNC mill.

Hammering cut out panels to form Marquis Module

Custom Jig used to clamp panels together while drying.

Progress picture of modules before linseed oil finish, paint details, and game features added.

Final Prototype

Game Modules

Tic-Tac Toe Board

Fully functional gear wall

Maze with hand-painted details

Marquis modules

Abacus wall

Drum wall

Marquis with matching storing bins and velvet curtains

Assembled Theater

Sensory Wall

Hand painted banner signs