A theatrical Victorian hat tailor made for the novella turned play “A Christmas Carol” that changes colour depending on Ebenezer Scrooge’s mood. Bah! Humbug!

Intended to add an extra dimension of theatrical drama, this hat aims to emphasise the character’s feelings and actions as well as revealing the character’s true feelings to the audience.

Design Blog

Our group decided to choose Project 1 : User-Interactive Theatrical Props because we felt that this project would give us enough creative freedom to design a unique product.

Brainstorming

Firstly, as a group we brainstormed different ideas, in order to decide in what direction we wanted to go with this project.

The two ideas that we chose to explore more were the Theatrical Hat and the Light up skull/map. We did further analysis regarding these two ideas.

Further Analysis

 

Defining the project

The theatre is an underrated space that requires high levels of accuracy and a staff that is coordinated and aware. This staff is composed of narrators, costume directors, technical directors, lighting designers, sound designers, so on and so forth. Time spent perfecting the roles of those individuals can be minimised with an interactive prop. We decided to use a hat due to its visible size and suitable location on the body to do more than just sit on the head.

Our  target audience are theatres, as the technology could be implemented in a range of different clothing items and accessories; but it could be especially useful for audience members who may suffer from certain disabilities such as: hearing impairment – as the lights will help convey emotions and tone changes,  autistism – as the lights and thoughts may help them to understand the characters better.

Hats are found profoundly in the theoretical scene and could be developed to serve a purpose. A lot can be done with a hat giving us, the designers, space to add an additional user-interactive option when initial elements are perfected. This prop is designed to clarify unspoken communication to the audience, add life to the actor and make the effort needed to synchronise lights, sounds and narrations minimal.

We want the hat to be as interactive as possible. Therefore, this hat will speak thoughts that a narrator would often have to verbalise. They will be in the voice of the actor and coming out of him without his lips moving, metaphorically representing thoughts. In addition, a bulb formed of LEDs will light up on the hat when the character has an idea and moods will be identified using different combinations of colours.

We decided to make a  Victorian style top hat, that could be used in the play “A Christmas Carol”.

User Interface Ideas

We wanted the main feature of the hat to be controllable LEDs that change colour depending on the character’s emotions. This can be turned on and off using buttons (on stage by the actor) though this would not be user friendly and could detract from the play. We then considered using a remote control that could be used behind stage. This is when we thought about using Wi-fi, which can be accessed by a laptop or phone allowing the stage crew to control the LED colours and patterns.

We decided this would be the most user friendly option as it would minimise error compared to using buttons on the hat that would need to be controlled by the actor which could confuse him, and allow errors to be made. A control would be a better alternative, but this could also confuse the backstage crew as they may not know how to use the buttons. Allowing the LEDs to be controlled by computer/phone would mean that the user is working with a familiar interface that works quickly and efficiently. This will allow the LED interaction to be integrated into a play seamlessly. The second interaction we wanted to include is sound, this could be used to communicate with the audience as the ghosts, while Scrooge is sleeping or to talk instead of Scrooge revealing his true thoughts and feelings. This will complement the mood LEDs.

Mood Board

Before starting to design we wanted to get some inspiration so we decided to make a Mood Board,  on Pinterest.

We thought that the aesthetic of small round LED lights looked efficient and were implemented in a wide majority of light up top hats. We included a picture of the light up fur coat as we want some of the light from the hat’s in the LED to shine on the the actors head/hear to highlight the fact that the colours are showing their thoughts.

Low-fi Prototypes

As we had decided on our idea and what features we wanted to include, we began prototyping.  Our initial prototype was very simple and shows the starting point of our idea, we initially were planning to have one LED and a button that would control the audio and the light. We then created more detailed diagrams of what we expected our hat to look like, LED placement and what we expected the wiring to be like inside the hat.

This was our original sketch of our deign.

We wanted to consider design features as well as the dimensions of the hat such as its size and its height. This drawing is a standard representation of a Victorian top hat. Though we tweaked its dimensions as we wanted it slightly longer so that it is of closer resemblance to the hat that Scrooge wears.

This is the second version of the top hat which has different luminous buttons dotted around the hat (to resemble effect in picture 4 of our Mood Board. This would be aesthetically pleasing and would manipulate the light in an interesting way but we also have to consider how it will fit in to the play we are targeting “A Christmas Carol”. We don’t think the look these buttons will achieve the look we want.

This third version of designs looks more fitting for the play we are targeting, as the lights are simple and blend in with the hat and will allow the LEDs to be seamlessly integrated into the top hat.

Meeting III – November 24th 

Designing the Project

Discuss a high-fi prototype and assign roles to enhance the quality while still speeding up the process. A list of the attributes and elements to be incorporated was written. Consequently, each individual chose their preferred option.

Tasks:

1. Research speaker, how to record and play sounds: Angele (Farah too)
2. LEDs for the lightbulb with suitable sound effect: Neve
3. Connect Arduino wirelessly: Marina
4. RGB LED for mood determination: Farah

 

Should the elements be controlled by a remote or the serial monitor? (input form)

What colours represent what emotions and how can that be clarified to the audience?

Make a hat or find a ready one?

High-fi Prototypes

Using floral stub wires to make the shape of the hat, we stuck these on to a cardboard base (base of hat) and covered the whole hat with a black material, sewing the edges together to close any gaps. We liked the aesthetic of the hat as well as the shape and the dimensions. The shape of the hat kept changing as the wire was malleable and as a result the hat was unstable and could not be worn if we were to make it in the same way but on a larger scale. We also tested shining an LED through it and found that the light shone through nicely but the material we used was too shear and would be see-through if many LEDs were to be used.

We then decided to make the hat out of corrugated plastic, as this would be very light and easy to form, especially for bending. It will also be easy to drill, in order to make precise holes for our LED lights. We used

Meeting IV & V – November 25th & 3rd December

Designing the Project

List of materials required for final material:

• Wireless Arduino
• Arduino Uno Kit given
• Speaker
• DFplayer
• WS2811 full colour LEDs

 

In our fifth meeting we decided that parts of the hardware should have been coded and finalised by members throughout based on the task chosen in the beginning and updated every morning according to amendments discussed. Thus, now it is time to combine the codes done by each individual and ensure they all fulfill their purposes with the wired components.

Components

LED Components

The LEDs should also be easy to control and not be too difficult to solder, as this could cause complications such as the solder between two LEDs weakening and breaking which would mean that none of the LEDs would work (as they are in series).

Choosing LEDs that can be individually controlled will permit the user to achieve a wider range of patterns and colours, allowing the hat to be adapted to specific scenarios and to the playwright’s vision for example.

The number of LEDs is also important as we do not want them to draw too much power and drain the battery before the play ends.

Therefore we chose to use WS2811 LED Pixels Light. Each pixel can be separately coded allowing an infinite combination of colours and patterns to be used. The specific ones we are using are also already attached with a wire so we do not have to do much soldering and avoid the complications mentioned above.

WI-FI: By using a Wemos D1 Mini ESP2866 that has built in wi-fi we can use this to control the components in the hat with a laptop/mobile.

Sound Components

The speakers would need to light and preferably of a darker colour so they can be camouflaged in the hat. The amount of power that they will draw will also be important as mentioned above so as not to drain the battery power.

One of the main features of our prop is its ability to say the wearers “inner thoughts”,  and to do this we envisioned the use of a speaker/piezo element to output simple catchphrases used by the character during the production. Through our research we found that we would need a speaker, instead of a piezo element because we want full audio files to be played rather than the melody or tune.We would also need to use a dfplayer as this enables data to be read off of a micro SD card, this is where the audio file will be saved. The audio player would work by loading the audio files from the micro SD card, a signal would then be generated and output through speakers connected to a digital pin, allowing the speakers to create sounds and play music.

The other components that we would need to create the audio player include:

• A transistor
• A resistor
• A Micro SD card
• Wires

However, there are some limitations, because we would be using a transistor instead of an amplifier we will need to convert the files to have specific dimensions (16kHz, mono channelled, 8-bit sample) as complex files can not be read.

https://maker.pro/arduino/projects/arduino-audio-player

As we want to have multiple thoughts available to the actor, we will have multiple audio files saved onto the micro SD card, that we hope to control with different buttons. Through researching audio players, we found that we are actually creating a modified MP3 player because of the addition of buttons.

When we begin creating our prop, we will start off with the audio player code as it’s less complex so that we can ensure all basic speaker components work and then begin modifying it to incorporate buttons and multiple files.

https://www.electronics-lab.com/project/mp3-player-using-arduino-dfplayer-mini/

Making the Top Hat

Firstly we had to determine what material we should use to make the base of the hat. After using wires to make the main frame of the mock-up hat prototype we decided to use a different material. After researching we decided that a suitable material would  be corrugated plastic as this would be light allowing the hat to be worn comfortably. This material can also be cut and shaped easily, by making precise slits in it to form round shapes which would be what we need to make the round part of the hat.

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We used wires to support the base of the hat and shaped the corrugated plastic around them, these wires were then later removed once the structure was steady. We also identified that different actors may play Scrooge on different days so we decided to add elastic to the inside of the base so that the hat can fit different hat sizes.

Adding the Electronics

We programmed the D1 Mini using ESPixelStick is a wireless E1. 31 sACN pixel controller that is made to control a string of LEDs. We soldered wires from the D1 Mini to the start of the LED string. We also used a connector jack to allow us to connect the LEDs to power.

Once this was completed and the LEDs were working, the LED were added into the holes previously made in the hat. And tested using the ESPixelStick interface.

 

User Interface

ESPixelStick allows you to change the colour and pattern of the lights using a simple and intuitive interface.

Makers Manual

Overview – Final Product

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Our final product is a wearable hat that has seamlessly integrated LEDs that can be controlled via WiFi using a D1 Mini. This can be done using a smartphone or computer. The hat is used to enhance the actor’s emotions by changing the colours and patterns of LEDs.

Tools and Supplies Needed

What was needed to make the hat prop:

• Corrugated plastic (2mm thickness) – 2 A3 sheets minimum
• Black velvet material – should have a slight sheerness
• Floral stub wire
• Hot glue gun
• Needle and cotton thread
• Blade
• Scissors

Inventory for electronics:

• WS2811 full colour LEDs
• Soldering gun (optional can use pins instead)
• Wemos D1 Mini ESP2866
• USB Cables
• Container to hold Arduino board
• Soldering gun and spare wires
• Battery pack (5V)

Layout and Circuit Diagrams

Build Section

How to make the hat

1. Measure the length and width of the desired actors head or use ..cmx..cm like we did.
2. Using cardboard, cut a circular section that will serve as the base of the top hat. Tweak this to fit your head size. Once this fits, it can be used as a template to cut out the corrugated plastic.

3. Trace this template over the corrugated plastic and cut it out using a blade or scissors, depending on the thickness you are using (we used 2mm thickness). Cut a slit in the back and add an elastic piece to allow the size of the hat to be adjustable.

4. Cut out another rectangular piece of corrugated plastic. One size of this should be the height you want your top hat to be and the other as long as the circumference of the middle of the top hat. Our dimensions are 29cm height x 24cm width, as shown. Make sure the lines run in parallel to the height of the hat. For every two lines make a groove (as shown by dashed lines below) in the plastic. Making sure to cut one side and not cut straight through the plastic. This will be form a perfect curved shape for the hat.

5. Measure how far you want your LEDs apart and and use a drill or blade to make holes where the LEDs will sit.

6. Cut out a circular shape out of the corrugated plastic to close off the top of the hat. Stick the pieces together using a hot glue gun.

7. Cut out fabric for each of these 3 parts of the hat and glue them in place, afterwards sew the edges together to complete the hat. Make sure you do not glue any of the holes closed.

Adding the electronics

1. The WS2811 LEDs have 3 wires attached to them. A red, blue and white wire. The red wire is responsible for power, the green is responsible for data and the white is for ground. Solder the green wire to the D4 pin of the D1 Mini, solder the white wire to ground. The white wire should be soldered to another white wire that is attached to a jack along with the red wire. This jack is connected to power. The D1 Mini should also be connected to a battery pack.
2. The D1 Mini should be programmed, using ESPixelstick, this is a controller deigned to control a single strand of pixels. Though we have also written code that can turn the lights on using an Arduino serial monitor.
3. Using your computer or phone, disconnect from your wi-fi networks and connect to the static IP address of the D1 Mini, now your chosen device should be able to control the lights.
4. Once everything is working add the lights to the holes you cut out in the hat and secure with a hot glue gun.
5. Put the D1 Mini into its case and tidy up the wires.
6. Enjoy the show!

Code Section

As we all had individual tasks, we each had code for our specific section that we would later come together to create our final piece.

Circuit Diagram

Testing Conducted and Shortcomings

Upon making the prototype we realised the fabric we used would be very important, in the way that we wanted the correct sheerness and also the right type of look. We opted to choose a thicker material after realising that our prototype was too thin and looked see-though when the light shone through it. Though the material we used was quite thick and proved difficult to sew in the way we wanted, which meant we had to use glue instead which did not achieve the vintage look we were aiming for. The lights also did not shine through as brightly as we wanted during the day, through we did consider that the theatre would be more dimly lit and these would serve well for this.

The battery pack we used is quite heavy and needs to put in the actor’s pocket, etc. this could weigh down the actor and we would need to do more research to find a more compact battery pack.