#12 Composites
For this assignment I was inspired by a wicker basket. At first I thought the basket itself could be inserted as a layer, but then decided I was going to do it only with 2 different types of fibers.
I designed a mold consisting of five layers of concentric circles, one larger than the other. Thus achieve a stepped mold simulating the shape of the basket. Each layer would have a thickness of 9mm, that was the thickness of the MDF would use. However it could use a thinner material, thus necessitating a greater number of layers to achieve the desired height, and obtaining a less stepped mold. However, for this assignment, the design worked well enough.
I exported in DXF the design and bring it to VCarve for cut it in the ShopBot.
Then I joined the cast layers, achieving both positive and negative. With the aim of good a good pressing to obtain a better final result.
I cut the fabrics in the Epilog. Designed a 18-point star, to avoid agglomeration on the circular mold.
The parameters for cutting jute were: Speed 66 Power 15 Freq 500
The parameters for cutting the tocuyo were: Speed 40 Power 35 Freq 500
I spread the mold with Vaseline and then covered with plastic wrap. This process is very important to unmold the final piece. If you're not careful it will be almost impossible to remove the epoxy resin once this is solid.
I followed the steps of the manufacturer to mix epoxy resin. In this case the ratios were 5 to 1 by weight. Once this process its done, you have a window only of 30 minutes before it starts solidifying.
First I put a layer of jute and dipped with resin. Then place a layer of coarse cotton and finally another layer of jute. Between each layer I was casting resin and verifying that the fabrics are well moistened with it.
Finally I covered everything with a layer of plastic wrap.
I closed the mold with the "top" and a press to give a good way.
After 18 hours removed the mold and remove the basket.
The end result was impressive. Despite some details like small air bubbles, I was quite pleased.
