Academy 2013

Composites


Composites is something I had never heard of a week ago.

Composites is a technique people use to make a fiber composites. In the beginning of the week I went to the website of how to make (almost) anything to get a better picture in my mind what I was going to do this week. In there I saw a lot of interesting projects from MIT students but of course I had to come up with an idea my self.
My first idea was to make eyeballs for my final project, made from fiber composites so it would be lightweight and easy to move with motors. The problem was that I thought it would be a waste of time to make a simple sphere because that is an easy shape.
I then thought of making a landscape model of the famous mountain Kilimanjaro. I downloaded a model of the mountain from Google and then exported it to Rhino 4.0. In Rhino I had to make the mountain solid and put a box under it so it would stand on something

Here is a picture of Kilimanjaro in Rhino

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Next thing to do was to cut it out in the Shopbot. The material I used was some green foam I found in our Fab Lab.

Here you can see the outcome from the Shopbot

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After I got the mold I had to figure out what material I was going to use to make the fiber composites. I went to all three hardware stores in Vestmannaeyjar and in the third one I found something called Davids Fastglas. The guys at the hardware store told me this was the only thing they got so I had to work with that.

Davids Fastglas

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In the package from Davids Fastglas was some glass fibre tissue which I used to make the fiber composite. I cut the tissue in stripes and placed it on the mountain after that I put Hardner in the Resin and painted it on Kilimanjaro. The instructions that came with the package where a bit weird because it said that I had to put 2 cm of Hardner with every 10 ml of Resin, I have no idea why they didn't just tell me how many milliliters I had to use for the Hardner instead of putting it in cm. Then I blended it and painted it on the mountain so the tissue got stuck on there. The tissues where a bit thin so I ripped down some newspaper to make it thicker.
This process had to be done quickly because the liquids started to dry up in 5 minuets.
The smell from the liquids was awful and should not be done inside but living in Iceland it's difficult to find a place with no wind.

Here is the mountain with newspaper and glass fibre tissue

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I did some experiments with vacuuming the air out of the mold but I wasn't good enough doing it. The plastic bag I used ether got stuck in the vacuum or the air got out somehow so I gave up on that after some experiments.

Here I am vacuuming the mold

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And in the end I painted the mountain white to cover up some boring news stories

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fablab
Vestmannaeyjar, Iceland