1. Project Overview
OrquiWall Smart System is a modular, wall-embedded intelligent orchid cultivation module designed to automate irrigation, monitor environmental variables, and integrate seamlessly into architectural spaces.
The project addresses the intersection between digital fabrication, embedded electronics, parametric design, and biophilic architecture. It is developed following the Design Thinking methodology and structured to integrate multiple Fab Academy assignments into a single cohesive bio-digital system.
The system combines:
- Automated irrigation control
- Substrate moisture monitoring
- Environmental sensing (temperature and humidity)
- Integrated user control panel
- Parametric and adaptable mechanical design
- Digital fabrication workflows (additive and subtractive)
Target Users
- Orchid enthusiasts
- Home users interested in smart gardening
- Interior designers integrating biophilic elements
- Smart home technology adopters
2. Problem Statement
Orchids are epiphytic plants with highly specialized biological requirements. Their survival depends on:
- Precise substrate humidity control
- Avoidance of waterlogging
- Continuous root ventilation
- Stable ambient conditions
Current Challenges
- Overwatering (primary cause of orchid death)
- Lack of real-time humidity measurement
- Manual, experience-dependent care
- Non-aesthetic commercial solutions
- No architectural integration
Existing commercial systems such as Click and Grow provide automated indoor gardening, but they are:
- Not designed specifically for orchid biology
- Not optimized for root aeration
- Not architecturally embedded
- Not customizable through digital fabrication
There is currently no wall-integrated intelligent orchid care system that combines precision irrigation, parametric fabrication, and aesthetic architectural design.
3. Design Thinking Methodology
1. Empathize
Urban environments reduce optimal conditions for orchid growth. Many orchid collectors and botanical enthusiasts struggle with humidity, light control, and irrigation stability. Through observation and interviews, a need for a controlled vertical smart garden was identified.
2. Define
Problem Statement: Design and fabricate a modular smart wall system capable of monitoring and controlling environmental variables such as humidity, temperature, irrigation cycles, and lighting conditions for orchids.
- Modular expandable panels
- Low energy consumption
- Integrated sensor network
- Automated irrigation
- Smart monitoring interface
3. Ideate
Concept development included:
- Stackable structural modules
- Custom PCB with environmental sensors
- Water distribution channel system
- Mobile monitoring via WiFi
4. Prototype
Rapid prototyping using 3D printed structural supports and laser-cut backing panels. Tolerance adjustments were applied using parametric modeling.
Initial Prototypes
Structural Prototype
Electronics Integration Prototype
Irrigation System Prototype
5. Test
- Humidity sensor calibration
- Water pump cycle validation
- Lighting intensity testing
- Structural resistance verification
- Power consumption measurement
4. Technical Specifications
Mechanical Specifications
- Wall-embedded niche module
- Parametric adaptable dimensions
- Internal drainage management
- Root ventilation channels
Electronic Specifications
- ESP32
- Capacitive moisture sensor
- DHT22
- Micro pump
- LED grow light
Functional Specifications
- Automatic irrigation
- Manual override
- Environmental monitoring
- Water level alert
5. System Architecture
- Sensing layer
- Processing layer
- Actuation layer
- Interface layer
- Communication layer
6. Bill of Materials (BOM)
| Component | Function | Fabricated / Purchased |
|---|---|---|
| ESP32 | Main controller | Purchased |
| Custom PCB | Electronic integration | Fabricated (Milling) |
| Moisture Sensor | Humidity measurement | Purchased |
| DHT22 | Temp & humidity | Purchased |
| Micro Pump | Irrigation | Purchased |
| 3D Printed Pot | Root ventilation | Fabricated |
| Laser Cut Frame | Structure | Fabricated |
| OLED Display | User interface | Purchased |
7. Parts to Fabricate
| Part | Process | Fab Academy Assignment |
|---|---|---|
| Wall Frame | Laser Cutting | Computer-Controlled Cutting |
| Orchid Pot | 3D Printing | 3D Printing |
| PCB | PCB Milling | Electronics Production |
| Front Panel | Molding & Casting | Molding and Casting |
8. Fab Academy Assignments Involved
| Week | Assignment | Application |
|---|---|---|
| Week 01 | Project Management | Documentation |
| Week 02 | CAD | Parametric modeling |
| Week 03 | Cutting | Frame fabrication |
| Week 04 | Electronics | PCB fabrication |
| Week 07 | Embedded Programming | Firmware |
| Week 14 | Final Integration | Testing |
9. Impact and Innovation
- Wall-integrated smart orchid care
- Parametric modular fabrication
- Fully digital workflow
- Open-source philosophy
- Scalable to vertical gardens
Integration of architecture, embedded electronics, digital fabrication, environmental sensing, and IoT systems into a single intelligent bio-digital product aligned with Fab Academy requirements.
10. Wall Frame Development : Computer-Aided Design & Computer-Controlled Cutting
Week 02 – Computer-Aided Design (Wall Frame Development)
The structural backbone of the OrquiWall Smart System is the Wall Frame. This component serves as the modular support structure where irrigation channels, electronic modules, and plant holders will be integrated. The design process was divided into two main phases: Rhino modeling and Grasshopper parametric optimization.
Concept01
Concept02
Phase 1 – Base Geometry Modeling in Rhino
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Step 1: Define Work Area
Set document units to centimeters. Define a base rectangle of 90 cm x 60 cm representing the total wall panel dimension.
Concept01
Concept02
Concept03
- Step 2: Create Structural Frame Border
Offset the external rectangle 4 cm inward to generate a perimeter structural frame. This creates rigidity and mounting margins.
Concept01
Concept02
Concept03
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Concept07
Assembly Process Video
⬇ Download Complete System (.3dm) ⬇ Download Single System (.3dm) ⬇ Download 3D Export (.OBJ / .3MF)- Step 3: Internal Grid Layout
Divide the interior surface into modular sections. A grid subdivision of 6 columns x 4 rows was created to allow modular plant holders.
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Concept02
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Assembly Process Video
- Step 4: Mounting Points
Add circular holes (8 mm diameter) in corner and central intersections for wall anchoring and structural reinforcement.- Step 5: Assembly Slots
Create interlocking tabs designed for 6 mm MDF thickness. Slot width was defined initially as 6 mm before kerf compensation.The base geometry was verified for structural balance, material optimization, and mechanical feasibility.
Phase 2 – Parametric Optimization in Grasshopper
To allow scalability and future modular expansion, the frame was reconstructed parametrically in Grasshopper.
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Step 1: Parameter Definition
Create sliders for:- Panel Width (default 90 cm)
- Panel Height (default 60 cm)
- Frame Thickness (4 cm)
- Grid Density (Rows & Columns)
- Material Thickness (6 mm)
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Step 2: Dynamic Grid Generation
Use "Divide Domain²" and "Isotrim" to generate adjustable modular sections. -
Step 3: Slot Parametrization
Define slot width as: Material Thickness - Kerf Compensation Example: 6 mm – 0.15 mm = 5.85 mm -
Step 4: Structural Reinforcement Pattern
Generate diagonal or honeycomb reinforcement patterns to reduce weight while maintaining rigidity. -
Step 5: 2D Flattening for Fabrication
Bake geometry into Rhino and organize parts in a flat layout ready for laser cutting.
The parametric model allows resizing the system without redesigning the entire structure, ensuring scalability of the OrquiWall Smart System.
Week 03 – Computer-Controlled Cutting (Laser Cutting Process)
After validating the digital model, fabrication was performed using laser cutting technology.
Material Specifications
- Material: MDF
- Thickness: 6 mm
- Panel Dimensions: 90 cm x 60 cm
- Cutting Method: COâ‚‚ Laser Cutter
Laser Cutting Workflow
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Step 1: File Preparation
Export final geometry as DXF format. Ensure all cutting lines are vector paths. Color code:- Red – Cutting lines
- Blue – Engraving (if needed)
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Step 2: Kerf Calibration
Perform a test cut on MDF 6 mm. Measure kerf using: Kerf = (Slot Width - Material Thickness) / 2 Adjust slot tolerances accordingly. -
Step 3: Machine Setup
Focus laser to material thickness. Configure power and speed parameters suitable for MDF 6 mm. Example baseline:- Power: 65–75%
- Speed: 15–20 mm/s
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Step 4: Cutting Execution
Place MDF sheet (90x60 cm) securely. Run cutting job and supervise process. -
Step 5: Post-Processing
Remove burnt residues. Light sanding of edges. Test-fit all interlocking joints. -
Step 6: Structural Assembly
Assemble slots and validate:- Mechanical rigidity
- Dimensional accuracy
- Wall mounting stability
The final result is a fully fabricated parametric wall frame, optimized for modular plant integration, electronic mounting, and irrigation routing.
- Step 2: Create Structural Frame Border