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Kazutoshi
Tsuda
11. composite (Apr 9, 2014)
Design and make a 3D mold, and produce a fiber composite
part in it
I made plant fiber composite materials by adopting an open mold
method in this week.
Cotton
Firstly, I made molds by vacuum forming.
![](11_2.jpg)
From left to right: extension cable reel, vacuum former,
and vacuum cleaner.
I used the outer surface shape of a pottery bowl as a mold. Last
winter I made the pottery bowl series, with the assistance of an
artist Takako Higashihata in Shigaraki, Japan. I trimmed the
foot ring of the bowl as shown below.
![](11_3.jpg)
Pottery bowl we made.
Transparent plastic sheet was heated to a pliable forming
temperature (60 Sec, and preheat time is 120 Sec), then formed
to the shape in the mold.
![](11_4.jpg)
The process of vacuum forming.
As a matrix of the composite, diatomite and powdered resin were
used. Diatomite is a naturally occurring siliceous sedimentary
rock and used as a filtration aid. These particles and water
were mixed with fingers until thoroughly combined, let sit in 30
min, and then mixed to the right consistency.
![](11_5.jpg)
The process of making matrix.
As a fiber of composite, cotton was practiced. The cotton was
made in the field of my family home since it was graft last
season.
![](11_6.jpg)
Cotton fiber composite in the mold.
![](11_1.jpg)
Cotton fiber composite in drying process.
Maybe it is preferred that softer mold (e.g. silicon
mold) and heavy fibers be used for the hard diatomite.
Burlap
I also tried to make another composite by using burlap as heavy
fibers. Burlap sheets were soaked in the mixture of diatomite and powdered
resin.
![](11_8.jpg)
The process of making burlap fiber composite.
![](11_9.jpg)
Burlap fiber composite with slightly curved.