Carnegie Mellon University · Bachelor of Design 2021–2022

Physicalization of AR/XR Experiences

Building tools to understand how AR behaves in real environments

Testing — Augmented Reality Tools for Design Prototyping title card
Overview

Designing AR experiences required understanding how the system behaves in context

Early in the project, I tried to design a complete AR experience. The prototype exposed issues with tracking stability, lighting conditions, and alignment between physical and digital elements.

Most of the learning came from building and testing rather than designing the final experience. That shifted the direction of the project.

I built six physical tools, each focused on a specific AR mechanic, to make these behaviors easier to test and reason about during design.

Program
BDes · Hybrid Environments
Role
Designer & Researcher
Tools
Unity · Arduino · ESP32 · Fabrication
Final system

A set of six tools for testing how AR behaves

The final system includes six physical tools, each designed to isolate and test a specific AR mechanic: tracking, occlusion, visual effects, and physical input.

All six prototyping tools laid out on a cutting mat
Physical forms, image targets, sensor modules, Arduino components, and AR test objects.

Each tool combines physical fabrication, image targets, and real-time AR interaction.

In motion

Six tools, six AR behaviors

Each prototype isolates one behavior so it can be tested directly.

01 Image Mapping

Single Image Mapping

Tests how surface finish, contrast, and printed detail affect tracking. Matte printed targets held more consistently, while reflective or low-contrast surfaces failed more often.

02 3D Masking

3D Masking

Tests how physical geometry can hide and reveal virtual content. Small mismatches between object and model made the illusion break quickly.

03 Image Mapping

Multiple Image Mapping

Tests how several image targets behave together. Spacing, target size, and angle changed how coherent the virtual layer felt.

04 Processing Effects

Processing Effects: Glass

Applies a shader effect to the live camera feed. The test showed how visual processing changes perception without changing physical geometry.

05 Physical Input

Reactive Lighting: Light Sensor

Uses ambient light as input, connecting a physical sensor to a virtual lamp. Environmental conditions became part of the interaction model.

06 Physical Input

Physical Control: Potentiometer

Maps an analog dial to the speed of a virtual fan. The connection between physical input and digital response became direct and easy to understand.

Problem

AR behavior changes depending on environment, material, and setup

Image tracking depends on surface quality and contrast. Occlusion depends on physical form. Lighting conditions affect reliability. Small changes in setup can produce very different results.

These factors were difficult to evaluate early because they only became visible during implementation.

In practice, tracking dropped when surfaces were too reflective. Occlusion broke when geometry was misaligned. Lighting changes affected consistency across sessions.

The challenge was creating a way to test these behaviors earlier and more consistently.

Constraints

The system was shaped by a few key constraints

Key constraints
Tracking

Surface quality and contrast determine stability.

Occlusion

Geometry must align precisely with digital models.

Environment

Lighting conditions affect consistency.

Direction

The project shifted from a single experience to a reusable testing system

The initial concept focused on a narrative AR experience built around physical objects. The first prototype showed that reliability of the underlying mechanics was the limiting factor.

I shifted toward tools that isolate and test those mechanics individually.

Project shift
01
Initial approach

Design a full AR experience.

02
Finding

Core issues came from system behavior.

03
New direction

Build tools to test individual mechanics.

Early prototypes exposed issues with tracking reliability and alignment, which led to the shift toward tool-based exploration.

Early 3D concept render
Original narrative AR concept.
Early cardboard cube prototypes
Early physical cube prototypes.
Unity editor with early AR prototype
Early AR masking test setup.
System

Breaking AR into testable behaviors

Instead of treating AR as a single system, I separated it into distinct behaviors. Each tool isolates one mechanic, making it easier to test and compare under different conditions.

01
Image Mapping

Tracking across surface types.

02
3D Masking

Occlusion using geometry.

03
Multiple Targets

Multi-marker stability.

04
Shaders

Camera-based effects.

05
Light Sensor

Environmental input.

06
Physical Input

Analog control mapping.

Tool details

Each tool had a physical and digital architecture

These diagrams document how each tool was constructed and how physical components mapped to AR behaviors.

Isometric diagram of all six prototyping tools
Overview diagram of the six tool system.
Component diagrams for tool 01 and tool 02
Image mapping and 3D masking details.
Component diagrams for tool 03 and tool 04
Multiple targets and shader effect details.
Component diagrams for tool 05 and tool 06
Sensor input and physical control details.
What this enabled

The tools made AR behavior easier to reason about during design

Instead of discovering issues late in development, I could test tracking, occlusion, and interaction earlier in the process.

This made it easier to design experiences that behaved consistently across different environments and reduced implementation rework.

Process

Iteration focused on form, material, and system integration

Most tools went through multiple iterations. Early versions either failed to track reliably or were too sensitive to setup conditions.

Adjusting surface treatments, marker density, and physical dimensions became part of the design process.

Form studies

Exploring how geometry affects occlusion and tracking stability.

Geometry and modularity
Early 3D masking model
Twelve cube form iterations
Cube cluster configuration options
Cube forms modeled for physical fabrication
Wireframe cube form variations

Material tests

Comparing surface finishes to understand their impact on tracking reliability.

Surface and tracking reliability
Range of image mapping materials
Wooden cube forms and image mapping cards
Laser etched cube forms
Full range of material finishes tested

Assembly

Integrating physical components, image targets, and electronics into working tools.

Building the tools
Assembled wooden cube cluster
Prototype iterations including 3D printed forms
Prototype tools laid out on cutting mat
Completed tools staged for testing
Close-up of prototype assembly components

In use

Testing how the system behaves across different environments and lighting conditions.

AR captures and tests
AR content visible through physical box outdoors
AR content visible through foam core box outdoors
AR 3D masking test outdoors
Animated prototype components on cutting mat
Animated AR masking test
Animated image mapping test
Learnings

What I learned from building the system

01
Material affects behavior

Tracking performance changed significantly depending on surface finish and contrast.

02
Testing reveals the real problem

Occlusion broke when geometry was slightly misaligned, and lighting affected reliability across sessions.

03
Mechanics need isolation

Separating AR behaviors into individual tools made each mechanic easier to understand.

Outcome

A reusable way to evaluate AR mechanics during design

The system provides a consistent way to test how AR behaves across different conditions. It allows earlier evaluation of constraints and more reliable design decisions.

This project shaped how I approach new systems. I start by testing constraints directly, then design from what holds up in practice.

6
Physicalized prototyping tools covering image mapping, 3D masking, shader effects, and physical sensor inputs.
4
Disciplines bridged: visual design, physical fabrication, electronics prototyping, and real-time software development.
1
Live capstone exhibition where visitors tested each mechanic firsthand.
All six prototyping tools laid out — final physical toolkit

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