Shape to Fabrication Team 4

Here are some process images from the Shape to Fabrication workshop. I was part of team 4, with Lawrence Friesen and David Rutten, who were designing a cast high tensile gypsum foundation to take a corian bench surface. The design was conceived as a close packing of egg shaped forms whose centroids lay either on the top or bottom surface. The interlocking egg forms would reduced the amount of material required to form the foundation to a minimum whilst maintaining a strong band of material through the centre of the foundation. The total volume of the foundation design was 0.34 m3. The moulds were CNC cut from expanded polystyrene and finished with PVA release agent. The moulds were then cast with a high strength gypsum usually used for taking moulds of teeth. Unfortunately the release agent did not work correctly and as such the moulds had to be forcefully removed using a water jet. This slowed down the process significantly and meant we only had time to release one of the three foundation blocks.

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