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P R O D U C T I O N -T E C H N I Q U E C E N T R A L - Q U E S T I O N S P I E

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Polyatherane foam is a material that is used in construction work. There is a aspect in the foam that is really interesting, the foam will expand when it is sprayed to any surface and it will stick to any surface. In the proces i discovered that the foam isn’t sticking to water. So how can i use water as a mould?

Fabric.

I used fabric to try and get a shape that is made out of one part. One piece of foam that is only using fabric to become functional.

In the design I tried to create a form that is not functional without each other. I used a interlock that will provide a stronger construction.

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C E N T R A L - Q U E S T I O N S

The one main question this semester was: How can I control spray foam?

Within this queston there came a couple of other questions: What kind of mould do I need?

How can I create a object only using foam and fabric?

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P R O D U C T I O N - T E C H N I Q U E - K N I T T I N G

This was my first production techniques I did research on.

I also made a couple of tests with knitting. But it wasn’t exiting enough to continue with using knitting as my technique.

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These are my experiments made from knitting.

The intervention is the most clear on the photo in the middle. To skip a stich you can create a from like this.

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P R O D U C T I O N - T E C H N I Q U E - R O P E

Making of rope is one of the techniques I really liked. I didn’t saw any future in the technique so I didn’t use it.

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P R O D U C T I O N - T E C H N I Q U E - M I R R O R

This was one of the production techniques I researched. Making of mirror was to complicated for this project. That why I didn’t use is further.

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F I R S T - E X P E R I M E N T S - F O A M

This is the first test I did with the spray foam. (left) The mapping of my moulding technique drawn by hand. (right)

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These are the first tests with spray foam. Using the expanding of the material. (left) Trying to get that into a shape. (middle) You see that the foam is getting shaped by the cup but the legs are growing by them self. (right)

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As you can see in the drawing below, left to right, I used a mould and put foam in there. The mould I used was made from wet fabric, I needed to use a wet surface to create a mould that wouldn’t stick to the foam. After spraying the foam in the mould you need to wait for a couple of hours till the foam is hardend. After that you gently peel of the foam and you get the shape you created.

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This wes the first test that worked by using wet fabric as a mould (left) Discovery that the spray foam isn;t sticking to water. (middel-right)

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More tests with different materials and shapes.

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More tests with different materials and shapes.

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The moulds used for the tests.

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The moulds used for the tests.

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These are the test that changed the use of the spray foam. Discovey water (left), Form and texture test (middle), Shape and looks test (right).

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The first idea to use water as a mould. (Left) First ideas of a product using spray foam and fabric.

(Middle-right)

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These are sketches of the first ideas of create a shape using one piece of spray foam and fabric.

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Sketches of bigger objects. I was thing of using a big pre designed shape and spraying foam in there to create a useable product.

(Left-middle) This was a design that contains a combination of two construction material, spray foam and steal, to create a modular cabinet.

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This is the final design sketch. (Left) I wanted to create a product only using foam and fabric. By using this design of 2 parts that wil interlock, you only can use the table when you have the 2 parts because it wil grow into each other. This is the contramould for the table. (middle) Close up of the design. (Right)

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Create a object that you doesn’t expect from this material.

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Use the interfering in the design.

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Use the material properties in the best way.

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Design from the material.

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I first made the pattern for the fabric. (left) This is the mould I made for the growing of the spray foam. (middle-right)

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Here you see the whole mould. I made a inside of styrofoam because it is easy to shape and strong enough. (left) While to foam was expeanding the outer mould came loose, so I put some heavy weight on it, 2 chairs and 2 stools. :)

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After I sprayed the foam in it was expanding. I made some holes were I can spray the foam in, and when it was in it could drip out. Otherwhise there would be to much pressure and it maybe could explode.

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In the pictures I used a black background to let the product pop out. I used one lamp to create shadows in the fouldings.

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The design it self is decent. I think from what i have done it is a good product dat shows the properties of the material.

By using the technique of using fabric as mould was hard because I never did this and I never saw someone use it. So with using a method I didn’t knew I did a good job.

The product it self is a good translation of what I wanted to do. Using fabric and foam only to create a product.

If you wanted to put the product in production you can. It wound be the same every time because of the foam. The mould is reusable, if you peel of the fabric you can sew the mould back together and you can use the mould again. I tried it twice now but i don’t really know what the l lifespan is of the mould.

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Past semester was different than I usually. The way of working was the other way around. Normally I design from my inspiration and then try to find the material what is best to use in the project. This time we started with the material to look at production techniques. It was a new way of working but a fun one to do. I had a lot of fun trying and exploring the material.

Making decisions This project was a hard one for me in making decisions. I normally have an idea and then try to make a product. Now I had techniques and test to try and make a product. This way of working makes taking decisions harder for me. That is because I need to take my time thinking of a product a bit longer when I work from a material.

Planning Because I need to think in a different way of a product. I need to make a better planning to create a clean idea in my head. Make a big schedule to create a overview so not very thing is stuck in my head.

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