Carbon fibre bowl 

The first of my new filaments I tested was the carbon fibre and I printed this on my home M3D printer.  It printed very easily and the support material was very easy to remove.  The finished material gave very fine lines and felt quite strong.  


I sanded down the top surface to see what the material would look like polished up.  I was really happy with the finish.  It gave a great shine.  

I decided that for this piece I would hand raise the other sections of the bowl using my 3D printed hammers.  ​

I used my laser sintered hammer initially to  planish the bowl.  Unfortunately this broke very soon in to the process.  The internal section looked very powdery due to the two part green process that Shapeways use.  I think this makes the metal much weaker.  I am going to try and reprint this on the direct steel sintering machine in Aberdeen and see if that makes any difference.  
 

I raised a smaller inside bowl to the piece in the same way.  However I had to use a regular planishing hammer to finish off both.  I must confess however that as the inside bowl was so small and fiddly I hand raised it to a certain point and then used the larger doming punch in the department to get the final shape.



I decided I liked the contrast of copper and black and oxidised the inside of the larger bowl and outside of the smaller.  I used a two part resin and mixed this in to the bowl.  I am regretting not testing this first as it seemed to react.  I am hoping that it will dry enough to sand back and make it look good but if this doesn’t work I will have to re-make it and test another type of resin. The other reason it may have reacted like this would be if there had been some moisture in the bowl before I added the resin.​


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Mixed 3D print tests

For the last ​few days I have been testing various 3D printing filaments. The first one I tested was carbon fibre mixed with PLA.  I printed it on a low quality setting, it took about eight hours to print and ran very smoothly.  The support material was very easy to remove.


I tested tough flexible filament in black.  This also printed off very well.  The great thing about this filament was that it fed into the printer with ease and doesn’t snap like some harder PLA.
The final printed object was flexible and I was able to squash it and it returned back to its original form.  I wasn’t particularly happy with the finished print quality though.  It was a bit messy and the support material was very difficult to remove due to the rubbery nature of the material.


I tested a heat change filament.  My home M3D printer had difficulties with this so I printed on the Up machine.  This worked well and printed smoothly and in a good quality.  The support was easily removed.  Although I don’t like the colour the change to white when held in the hand. I have another colour change filament to try which is a little more subtle.

My favourite filament out of this range has to be the brass fill PLA.  I printed this on the UP.  It printed beautifully and the support was easy to remove.  The piece has a really nice weight and sparkles like brass in the sun light.

I also printed a wood fill version.  Initially this was printed on the UP with 1.75mm filament.  This clogged up the machine so it was printed on the larger printer in a thicker filament which worked.  The finished item smells like wood.  When filed it feels like a cross between wood and plastic.  The bowl has a nice weight but I don’t like the messy nodules the printer has left in some areas.  

Laser cut bowl 

Today I tried laser cutting some of my bowl designs.  I cut one version that slots in to the top and bottom and one that just slots in to a bottom section with a flat cut top. 


I slotted the pieces together and glued them in to position,  I found that the design was a little tight in the centre section.  It was quite difficult to judge what the line thickness should be in CAD for the slots as the laser melts some material around it.  

After squeezing together the plastic the piece smashed so I will need to redesign it for tomorrow. 

3D printed bowl

I recently got some tough flexible plastic filament for my M3D printer.  I decided to test it using the design I had produced for my CNC bowl.  It took 25 hours to print.  The great thing about the material is that I didn’t have any problems with it snapping mid build as I have with regular filament. 



Once the print was finished I removed it from the bed and started to remove the support material with pliers.  Although the material is very strong and flexible it was quite difficult to remove the supports in a clean way.

Mixed material bowls

I have been spending the last few weeks designing various bowls that I can test materials with.  I plan to make all of the outside sections through direct processes such as laser cutting, syntering and 3D printing.  All the internal bowls I plan to make using traditional techniques only using modern technology to make the tooling.
Laser cutting ideas:

laserbowl1laserbowl2

Laser syntering in steel:

steelsteel2steel3

CNC milling ideas:

walnutbowl1walnutbowl2walnutbowl3walnutbowl4walnutbowl5

Egg Cups

I have been really enjoying raising metal in the workshop over the last few months. Aside from getting very toned in one arm, there is something very therapeutic about creating objects by hand.


I first cut out two disks 75mm radius.  I later had to cut this down by about 12mm so I should have begun with 62-64mm.  This means the edge on this piece will be thinner than I would like. 

I have almost got them to the shape I like but want to bring in an egg next week to make sure they fit perfectly. 

I plan to 3D print and cast matching bases for them.

Rat Brain Cell Colander

I have decided that as a little tongue and cheek I will add a rat handle to my rat brain cell colander.  When I thought about it last week I had a giggle to myself about having a rat hanging on my wall and watching me whilst cooking my pasta in my shipping container.  The rats tail doubles back to allow it to be hung from the wall.  I have spent a few days modelling this and I still need to finish off the bowl and think about how I am going to attach the rat handle to the bowl.  I want to try and stay away from using artificial chemical bonding (aka glue), I may add in holes that I can try and plastic weld the two together with my 3D doodle pen.  My other idea is to try and make a clip out of the handle that the hands will attach to.

rat3

 

Light jig

i got my 3D printed resin jig back a few days ago. It has been nearly ten years since I printed my last jig on the SLA resin machine at RCA. This one was printed on a much more modern machine called a form lab which can print in various types of resin. My model had to be scaled down slightly to fit the bed size of the machine.  The result of this has been that the tube sizes were too small and closed up making the jig unusable.  Although it looks great as an object I will need to rebuild this in CAD.


Colander

I have been working a lot on my second colander design idea.  This has taken me much longer to create than the one I posted earlier this week.  I prefer this design however It isn’t yet finished and I have some tweaking in T-splines to do.  I also need to design the handle so that this can be printed separately as it is too large for the printer bed size.

COLLANDERBRAINCELL

I am a little concerned about the size of some of the gaps in the piece.  I will print a version as it is after the tweaks to test and I can also use this model to develop a fruit bowl for my container.

COLLANDERBRAINCELL3COLLANDERBRAINCELL2

 

Colander

For the last two weeks I have been settling in to my new life in Dundee.  I have been getting equated with the university campus and finding my way around.  I have been buying glaze for my shot glasses as well as printing more press moulds.

Today I set myself the task of designing a colander for the kitchen of my shipping container.  I find the kitchen implements quite and interesting area of my study as it is both a tool and could be 3D printed or I could also go down the line of hand building them.

I feel that as I have to build everything in my house some simpler items such as colanders should be directly 3D printed to save time.  However I am still aware that I would like to focus on the aesthetics of the piece.

I had a few ideas I ran through in my sketchbook looking at cell structures and geodesic domes.  Here is the first CAD model I have made:

collinder

This design was inspired by the roof design’s of both Buckminster Fuller’s domes and Grimshaw’s Eden Project.  The only concern I have is if the holes in the piece are too big it will be impractical and food will fall through it.  I will print this to test first.