The completed eight-metre cardboard Whale with its makers at Marina Square
Fab Academy final project · 2023

The Cardboard Whale That Came to Life

An eight-metre sculpture where sustainable cardboard construction, digital fabrication, motion, and light meet public participation.

01 · Story

An unlikely material. A gentle giant.

The Whale began with a simple question: how far could cardboard be pushed as a serious material for public art, engineering, and interaction?

A life-size whale took shape from cardboard—an everyday material usually treated as disposable. The eight-metre sculpture became a symbol of creativity and environmental consciousness, responding to visitors through motion and soft LED light.

The project followed a spiral development process. A PIR sensor and servo first introduced movement; subsequent iterations added lighting along the mouth, synchronised with the rhythm of a visitor gently touching the Whale beneath its eye.

Walkthrough of the completed Whale at Marina Square. Video by Minn, 25 May 2023.
01

The spark

Electronic design, 3D printing, flatbed cutting, and embedded programming were combined into one integrated work. Each stage tested whether the form and interactive system could grow together.

02

The vision

The project was conceived for collaborative making at FAB23 Bhutan: a sculpture shaped not by one maker, but by a network of participants contributing skills, ideas, and energy.

03

The design

The Whale was modelled in Blender, unfolded, and arranged as hundreds of templates in Adobe Illustrator to fit 1.4 × 1.1-metre cardboard sheets.

04

The interaction

A custom RP2040 board, PIR sensing, servo actuation, and LED lighting gave the sculpture a quiet sense of life and a response to human kindness.

05

The challenge

Scale brought practical questions: labour, cost, logistics, structural life, and whether an eight-metre build could be justified. Prototyping turned those uncertainties into decisions.

06

The shared result

The completed Singapore prototype proved the construction system and became a platform for collaboration, storytelling, and future public projects.

02 · Presentation

Presented on 7 June 2023.

The project was presented fourth in the Fab Academy final-project schedule. The slide and recorded presentation document the concept, fabrication process, electronics, and completed installation.

Final project presentation slide for the Cardboard Whale
Final-project presentation slide
Recorded Fab Academy presentation
View the 2023 presentation schedule
03 · Build

From model to movement.

The build combined a low-poly cardboard shell with a custom electronic system, small-scale production methods, and a process designed for collaborative assembly.

1.1

What does it do?

The life-size cardboard Whale turns a sustainable material into an interactive public experience. A motion sensor and servo introduce movement, while LED strips along the mouth respond when visitors gently pat the area beneath its eye.

The project uses a spiral development approach, integrating electronic design and production, 3D printing, flatbed cutting, embedded programming, and full-scale assembly.

1.2

Who inspired the work?

The project draws on a wider practice of cardboard sculpture while extending it to the scale and collaborative context of a global Fab conference. Key inspirations include Joseph DeLappe, Kiel Johnson, and Horst Kiechle.

Joseph DeLappe’s cardboard Gandhi work
Joseph DeLappe
A cardboard artwork by Kiel Johnson
Kiel Johnson
A geometric cardboard work by Horst Kiechle
Horst Kiechle
1.3

What was designed?

An endangered marine animal was modelled in Blender, unfolded, and laid out as hundreds of panels in Adobe Illustrator. A smaller die-cut Whale was also designed for easy replication as a participant keepsake.

1.4

Parts and systems

  • Eight-metre indoor cardboard shell
  • QR-code vinyl linking to instructions
  • Custom PCB with Seeed Studio RP2040
  • 3D-printed electronics enclosure
1.5

Processes used

  • Flatbed cutting for A- and E-flute cardboard
  • 3D printing for the PCB enclosure
  • CNC milling for the electronic board
  • Embedded programming for sensors and actuators
  • Vinyl printing and cutting
1.6

Questions answered

  • How many person-hours are required?
  • Does the work need to be life-size?
  • How can fabrication and logistics be funded?
1.7

How was it evaluated?

  1. Complete a working full-scale prototype in Singapore through spiral development.
  2. Plan the fabrication and logistics required to take the project to Bhutan.
  3. Invite participants to build together and create a shared final moment.
  4. Open the Whale to further collaboration—from projection mapping and mechanisms to drawing directly on its surface.
04 · Materials

Materials and components.

A small electronic system supports the interaction, while heavy-duty cardboard and acrylic colour form the physical and visual body of the Whale.

ItemDescriptionPriceSource
Seeed Studio XIAO RP2040ARM Cortex-M0+ MCU 32-bit embedded evaluation board$7.81DigiKey
RC servomotor, 4.8VPositional-rotation hobby servomotor$5.24DigiKey
PIR motion sensor HC-SR501Detects movement within approximately seven metres$3.60Kuriosity
Male-to-male jumper wires20cm wires supplied in a strip of 40$3.60Kuriosity
Heavy-duty cardboard2.3 × 1.4m sheets, 10mm thick$28.00Tri-Wall
Daler-Rowney Graduate acrylic colour500ml squeezable pots in multiple colours$13.38Art Friend