Screen materials

[choffmann]

Hello!

I bought 3 Mitsubishi projectors for my surround view setup. I am not yet decided on the way I will build my "wrap-around" screen. I like the plywood boards joining in a perfect radius, but I think its not easy to build this and I fear, that the surface may become uneven with time with the wooden boards changing their shape a little bit.
I also think about some curtain solution, which would be easier, because I can mount a perfectly curved curtain rail on the ceiling and even throw it aside. Although I favour this second idea, I don´t know how to exclude or diminish the wrinkles of the curtain, it must be stretched in some way.
Has somebody a good idea for this issue?
Also, if I use some kind of cloth/curtain, what properties should it have?

Cheers
Chris

[jackpilot]

Just out of my hat..has someone tried to curve 1/4" thick Gypsum boards on a wood frame.
Also thin PVC sheets could do.
Check my post on Coroplast too , at least as a temporary test "bed" .
Dirt cheap, super light, can be bent at will and surprisingly reflective.

http://www.cockpitbuilders.com/community/index.php?topic=1333.msg9935#msg9935

[makoy]

I use 2mm matta white PVS.
Size is 300x160 cm.
Only thing what need to do, is stand.
No painting or sanding...easy and quik way to do it.
Prize was about 40 euro.

Marco

[Kennair]

Just out of my hat..has someone tried to curve 1/4" thick Gypsum boards on a wood frame.
Also thin PVC sheets could do.
Check my post on Coroplast too , at least as a temporary test "bed" .
Dirt cheap, super light, can be bent at will and surprisingly reflective.

http://www.cockpitbuilders.com/community/index.php?topic=1333.msg9935#msg9935

Jack, yes we've used 10mm Gypsum curved for a total of 10m x 2.4m.  I wasn't there when it was done, but my business partner Richard says it was tough work and he wished he'd used 8 or 6mm (5/16" or 1/4") for an easier bend.  Lots of vertical struts to give it an even curve though.

Ken.

[jackpilot]

I said that because I remember doing the kitchen ceiling and carrying these over my head. They were bending so bad that I could'nt see in front . 

[Maurice]

I used 4X8 ft - 1/4 inch flexible drywall (gypsum) and that stuff bends very easily lengthwise. You do need to have  a sturdy wall structure to hold it though. I made a big mistake with mine as I used 2x4 studs held only at the bottom. That worked quite well for the bottom row of drywall but I had a heck of a time with the junctions on the top row as the drywall sheets were making a sharp angle at the junctions and I had to use tons of drywall compound to get rid of the angle and make a nice curve. I should also have staggered the joints and that would have helped a lot but I didn't and I paid the price.

The end result turned out OK after a lot of filling & sanding but I would certainly use the same stuff again with a better wall structure. You can see what I mean in some of these pictures:
Note. Screen has been primed only so far and views still not fully aligned with Nthusim

http://entertainment.webshots.com/album/578393990fLjxzB

http://entertainment.webshots.com/album/579535629qeiEOT

Maurice

[fulcrum]

I don't know if this would fit your requirements but we produce large - up to 14' - curved sandwich panels.
They are very light, very stable in shape and can be produced with any degree of curvature, pretty much any skin material you choose.
www.fulcrumcomposites.com

[Speedbird17]

Chris

I am playing around with Foam PVC Board. Very light and easy to bend. Also available in large sizes. Sourced mine here: http://www.roberthornedirect.co.uk/Foam-PVC-Sheet/

Regards

[choffmann]

Thank you all for your ideas.

I went to the local DIY store today and bought some kind of Foamex boards, 1 x 1.4m. This pic shows the boards around the shell:




Then I cut some wooden stands and milled a notch in the shape of the radius I want (1.65 m). This was no easy job, as the boards withstand the bending quite a lot. The boards fit snug into the notch  and maybe won´t need other support to stand upright. I will put the boards one next to the other to complete the surround wall. Since they are all separate, I can easily store them somewhere else.
Here ´s how it looks like (one unit):



I also finished the ceiling triangles:





Cheers
Chris

[XOrionFE]

Looks great Chris.  I love the ceiling triangle also!

Scott

[Vectro]

Here is how we did it:
http://www.lentosimulaattori.1g.fi/kuvat/Visual+system+testing/visu2.jpg
http://www.lentosimulaattori.1g.fi/kuvat/Visual+system+testing/visu1.jpg
http://www.lentosimulaattori.1g.fi/kuvat/Visual%20system%20testing/16102009352.jpg
http://www.lentosimulaattori.1g.fi/kuvat/Visual%20system%20testing/IMG_1611.JPG

the frame is plywood and the surface is MDF. 8 separate modules, painted with a special video projector gray paint.