12. composites

 

For the composites assignment, I want to create something using steel as reinforcement on a concrete matrix. Nothing new there, but it is for me. I also want to try making a semiwoven lattice using CNC bending of 1/8″ diameter carbon steel. I´m lucky to have at hand an small desktop bender, a DiWire, wich is (hopefully. ) up to the task.

The subject object for this assignment is an small stool, which will have a seat volume made of this orthogonal steel structure, which in turn will be put on an EPS mold cavity made by a CNC hot wire cutter. The concrete is also reinforced using fine gravel. Here are some proces sketches explaining the object and method.

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Since the DiWire bender software works with .SVG files, I had to convert the Alias generated DWG files in Adobe Illustrator. Once there, I´ve opened them, checked scale, lenght and material setup to feed the steel wire. Once I´ve started bending, I tagged them with postits to avoid hassle while assemblying.

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After bending them, I cut / trimmed the excess rod with a big bolt cutter, which was the only tool I had at hand ( I wasn´t allowed to cut the rod with the shear for fear of leaving indentations on its edge.) Once cut I had to bend some parts back to elliminate springback, and welded the transversal loops. After that I laser-cut a pair of simple assembly jigs with the correct spacing between sections, and to allow me to insert the other orthogonally placed wires.

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Tying up the perimetral intersections to improve stiffness.  Cutting the mold for concrete casting in EPS using a CNC hot wire cutter:

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Setting up the steel structure in the mold, concrete preparation and casting. I expect to release the mold tomorrow around mid – day. There where slight trimming errors and springback deformation in the wire structure which resulted in uneveness far from the nice and exact CAD drawing. Not very funny thing but definitely a learning experience on something I´ve never did before. In my defense I can only said the famous (designers.) Campana Brothers are famous for the deliberate exploitation of their inaccuracy… 😀

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After leaving it for 16 hours, I considered it was ready for demoulding, but since it´s still a little damp, I´ll try a seating test on it in 10 hours more.

demolding

 

 

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To access the files for this assignment, please go here:

FabAcademy assignment files