Plastic Elegance

Plastic Elegance Elevating plastic bags to new heights of form and function with heat lamination and formal exploration.

Hanieh Sotudeh Diploma Studio: Tapping into Urban Waste for Sustainable Building Materials Julio Diarte Almada Spring 2023

Index Abstract ..............................................................................................................................................

Introduction ......................................................................................................................................

Context ............................................................................................................

Opportunities ...............................................................................................

Goals and methods.....................................................................................

Precedent............................................................................................................................................

Hugo McCloud’s artworks use plastic bags instead of paint ..........

Museo Aero Solar.................................................................................................

BagCyclo ..................................................................................................................

Recycle bags to decorate the house ...........................................................

Recy blocks .............................................................................................................

Test Material .....................................................................................................................................

Design .................................................................................................................................................

Prototypes ..........................................................................................................................................

Experiment 1 .................................................................................................

Experiment 2 .................................................................................................

Experiment 3 .................................................................................................

Final Proposal.....................................................................................................................................

Conclusion ..........................................................................................................................................

Bibliography.......................................................................................................................................

Abstract The global consumption of plastic bags has resulted in significant environmental pollution, and finding ways to repurpose them is becoming increasingly important.

This project aims to explore the potential of plastic bags as building materials through heat lamination. By testing the structural capabilities of multiple layers of plastic bags, this project will evaluate the impact of different conditions, such as different types of thickness, numbers of layers, Iron temperature and fabrication workflow, on their performance.

Past applications of plastic bags in architecture and interior design include weaving floor components, creating plastic yards for use in travel mattress, and molding plastic into jewelry, saucers, etc. This project aims to build on these existing applications and investigate the possibilities of heat lamination as a way to create functional and aesthetically pleasing building components.

The proposed material workflow for this project will begin by studying the behavior of plastic bags under heating and ironing. A dataset of different conditions will be created to identify the optimal conditions for creating building components, such as interior partitions. The project will also explore alternative techniques like reinforcing the material using a secondary material, using molds to create modular components or double curved surfaces.

The final outcome of this project will be a comprehensive study of the architectural and design potential of plastic bags and an exploration of innovative solutions for repurposing this abundant and often-discarded material. The results of this study will contribute to a growing body of research on sustainable materials and provide valuable insights into the potential of plastic bags as building materials.

Introduction The excessive use of plastic bags globally has led to a significant environmental challenge. The world generates 300 million tons of plastic waste annually, with only 9% of it being recycled (World Economic Forum, 2016). Plastic bags are a ubiquitous and problematic waste product of plastics. In the United States alone, an estimated 100 billion plastic bags are used each year, with only 1-3% of them being recycled (United Nations Environment Programme, 2018). Plastic bags, when not properly disposed of, can end up in landfills, oceans, and natural environments, where they can take hundreds of years to degrade, posing a severe threat to wildlife and ecosystems. Thus, finding innovative ways to repurpose plastic bags has become increasingly important.

The repurposing of plastic bags presents a significant opportunity to reduce environmental pollution and contribute to sustainable development. Plastic bags can be repurposed for different applications, including weaving floor components, creating plastic yards for use in travel mattresses, molding plastic into jewelry and saucers.

Plastic recycling involves several stages, including sorting, washing, shredding, and melting. (Thompson et al., 2009). Repurposing plastic bags at different stages of the recycling process presents unique opportunities. For example, using recycled plastic bags that have been shredded and melted can create plastic lumber, which can be used as a building material (Sharma et al., 2021). Similarly, using recycled plastic bags as raw material for 3D printing can create a range of objects, including prosthetics, toys, and household items (Kaner et al., 2019).

The goal of this project is to explore the potential of plastic bags as building materials through heat lamination. Specifically, the project seeks to test the structural capabilities of multiple layers of plastic bags and evaluate the impact of different conditions, such as thickness, number of layers, iron temperature, and fabrication workflow, on their performance. The project aims to build on existing applications of plastic bags in architecture and interior design and investigate the possibilities of heat lamination to create functional and aesthetically pleasing building components, such as interior partitions.

To achieve these goals, the project will begin by studying the behavior of plastic bags under heating and ironing. A dataset of different conditions will be created to identify the optimal conditions for creating building components, including the type of plastic bags, thickness, number of layers, and iron temperature. The project will also explore alternative techniques, such as reinforcing the material using a secondary material, using molds to create modular components, or creating double-curved surfaces.

Different explorations will be conducted on the formal characteristics of heated layers of plastic to be able to reach single curve and double curve panels. For doing so, different methods have been studied. First, different ways of building molds were tested to be able to form the plastic layers between them, including using a waffle mold and a mold from the panels outline. Moreover, while ironing the material, different fabrication methods were tested. First, all of the layers were ironed at the same time, which resulted in air bubbles forming in between the layers. In the second try, ironing was done between adding each layer of plastic bag to reach a solid, unified structure without any air bubbles.

Precedent

Precedent Hugo McCloud’s artworks use plastic bags instead of paint

Fig 2. Together shows women carrying goods across the border of Ceuta, a Spanish autonomous city in Morocco

Fig 1. Several of the artworks show refugees crossing the Mediterranean Sea from Libya

Fig 3. With all your Might is one of several Fig 4. Each piece is a collage of pieces that show goods being transported hundreds or thousands of small plastic by labourers shreds

https://www.dezeen.com/2021/02/16/hugo-mccloud-burdened-sean-kelly-gallery/

Museo Aero Solar

Fig 5. Museo Aero Solar is a floating museum made entirely of re-used plastic bags donated by the public. The device floats, completely fossil-fuel free, powered only by the heat of the sun.

Recycle bags to decorate the house

Fig 9. recycled lampshades

http://diarioartesanal.com/las-mejores-ideas-para-reciclar-bolsas-plasticas/

https://normanarts.org/news/2019/6/norman-arts-council-to-launch-collaborative-community-artwork-project-on-summer-solstice

BagCyclo* BagCyclo proposes a machine that will transform discarded plastic bags into a strong, flexible textile, to be used in architectural applica­ tions. While plastic bags are known to be flimsy, they become incredibly strong when spun into strands and woven together to create a surface.

Fig 6. Detail of mockup model of proposed floor system

Fig 7. This model made of woven plastic bags stretched between steel members was able to withstand the weight of a person

Fig 8. the process of manipulation that the plastic bags underwent to become a textile

* Lucy Flieger

https://normanarts.org/news/2019/6/norman-arts-council-to-launch-collaborative-community-artwork-project-on-summer-solstice

Material Test

Research Intention: The intention of this project is to explore the potential of plastic bags as a building material through heat lamination. The goal is to repurpose plastic bags as a sustainable and eco-friendly solution to reduce environmental pollution and contribute to sustainable development. The project will investigate the structural capabilities of multiple layers of plastic bags and evaluate the impact of different conditions, such as thickness, number of layers, iron temperature, and fabrication workflow on their performance.

To achieve this, the project will conduct material tests to assess the durability of different numbers of layers and the effect of reinforcement on the material. The test scale will be gradually increased to test larger panels and their formal capability. The possibility of shaping double-curve and single-curve panels with and without reinforcement will be investigated. Different types of molds will be tested to determine their effectiveness in producing the desired shapes.

The ultimate goal of this project is to design and construct a plastic pavilion that demonstrates the potential of using recycled plastic bags as a sustainable and eco-friendly building material. This pavilion will serve as a proof of concept for future construction projects using this material and will raise awareness about the importance of sustainable building practices.

Material Test Diagrams The process involves taking a plastic bag and folding it three times, which creates six layers of plastic. Then, the folded plastic bags are ironed in two different ways. The first way is to iron all the folded plastic bags together at the same time, but this method can create air bubbles between the layers, making the material less durable. Alternatively, ironing two layers of plastic at a time and then adding more layers on top of them can help to fuse the layers together without creating air bubbles, resulting in a stronger, more durable material.

To further test the durability of the folded and ironed plastic bags, different types of reinforcements such as aluminum frames and chicken mesh nets were added to the bags. The goal was to see if these reinforcements could further increase the strength and durability of the bags. The results of the test showed that the folding and ironing process, along with the use of reinforcements, significantly increased the strength of the plastic bags, making them suitable for multiple uses.

Material Test - 50 µ - 4*6 Rectangles 6 Layer, 0.3 mm

12 Layer, 0.6 mm

18 Layer, 0.9 mm

35 Layer, 1.8 mm

54 Layer, 2.7 mm

72 Layer, 3.6 mm

90 Layer, 4.5 mm

108 Layer, 5.4 mm

Layers

Temperature

Degree

Time

Each Layer Thickness (μ)

Final Thickness (mm)

6

200

4

15

50

0.3

12

200

4

30

50

0.6

18

200

4

50

50

0.9

36

200

4

55

50

1.8

54

200

4

90

50

2.7

72

200

4

110

50

3.6

90

200

4

180

50

4.5

108

200

4

480

50

5.4

Layers

Temperature

Degree

Time

Each Layer Thickness (μ)

Final Thickness (mm) 1.5

6

400

6

15

250

12

400

6

30

250

3

18

400

6

60

250

4.5

36

400

6

90

250

9

54

400

6

120

250

13.5

Material Test - 250 µ 6 Layer, 0.3 mm

12 Layer, 0.6 mm

18 Layer, 1.8 mm

36 Layer, 9 mm

54 Layer, 13.5 mm

36 Layer, 9 mm

Layers

Temperature

Degree

Time

Each Layer Thickness (μ)

Final Thickness (mm)

6

200

4

15

50

0.3

12

200

4

30

50

0.6

18

200

4

50

50

0.9

36

200

4

55

50

1.8

54

200

4

90

50

2.7

72

200

4

110

50

3.6

90

200

4

180

50

4.5

108

200

4

480

50

5.4

Layers

Temperature

Degree

Time

Each Layer Thickness (μ)

Final Thickness (mm) 1.5

6

400

6

15

250

12

400

6

30

250

3

18

400

6

60

250

4.5

36

400

6

90

250

9

54

400

6

120

250

13.5

Design Steps A final design method for creating plastic panels involved testing a random double curve surface and forming the plastic after ironing it. To ensure that the plastic took the form of the mold, a heat gun was used after placing the plastic in the mold. The plastic was melted down to a degree that would allow it to take on the shape of the mold, and then cooled down.

The resulting plastic panel was strong and durable, and could be joined to the next panel by reheating the edges and joining them together. This process allowed for the creation of larger structures, such as walls or roofs, by joining multiple panels together.

The final design method proved to be effective in creating strong and durable plastic panels that can be used for a variety of applications.

Prototypes

Experiment 1

Experiment 1 - Mold Number 1 - Waffel

Experiment 2 - Mold Number 2

Experiment 1 - Mold Number 1 - Waffel

Experiment 2 & 3 - Mold Number 2

Experiment 2 - Mold Number 2

Experiment 3 - Mold Number 2 - Mesh Reinforcement

Plastic sheet fabrication Using parchment paper as a protective layer

Plastic sheet fabrication Layering plastic bags on top of parchment paper

Plastic sheet fabrication

Ironing multiple layers of plastic bags together to create a single, strong plastic sheet

Plastic sheet fabrication A strong, water-resistant and versatile plastic sheet

Waffle wooden mold

Waffle wooden mold

Plastic panels Forming the plastic sheet using heat gun

Plastic panels Heated plastic bags reshape to the specific form of mold

The top part of the wooden mold used to shape the plastic sheet.

The top part of the wooden mold being slid into the bottom section

Waffle wooden mold Top and bottom sliding to each other

Plastic panels Panel after it has been removed from the mold

Waffle wooden mold The top and bottom parts of the mold are locked together,

Plastic panels Panels will be joined together to create a larger, customshaped plastic product.

Final Product

Possible Variations

Conclusion: The excessive use of plastic bags globally has led to a significant environmental challenge, with only a small percentage of it being recycled. Finding innovative ways to repurpose plastic bags has become increasingly important to reduce environmental pollution and contribute to sustainable development. The project aims to explore the potential of plastic bags as a building material through heat lamination, and the results show promising possibilities for repurposing plastic bags as a sustainable building material.

The project has investigated the structural capabilities of multiple layers of plastic bags and evaluated the impact of different conditions, such as thickness, number of layers, iron temperature, and fabrication workflow on their performance. The project has also explored alternative techniques, such as reinforcing the material using a secondary material, using molds to create modular components, or creating double-curved surfaces.

Different explorations have been conducted on the formal characteristics of heated layers of plastic to be able to reach single curve and double curve panels. The project has tested different ways of building molds to form the plastic layers between them, including using a waffle mold and a mold from the panels outline. Moreover, different fabrication methods were tested, and ironing was done between adding each layer of plastic bags to reach a solid, unified structure without any air bubbles.

The project’s ultimate aim is to provide a sustainable and eco-friendly solution to the excessive use of plastic bags and contribute to the development of sustainable architecture and interior design. By exploring the potential of plastic bags as a building material, the project aims to inspire designers, architects, and manufacturers to rethink their material choices and contribute to a more sustainable future.

The results of the project show that plastic bags can be repurposed as a building material through heat lamination, and the material can achieve a high level of structural integrity. The use of plastic bags as a building material has the potential to reduce environmental pollution, contribute to sustainable development, and inspire designers to create sustainable and innovative solutions.

However, there are still challenges and limitations to the use of plastic bags as a building material. One of the main challenges is to find the best method of heat lamination that can facilitate generating double curve surfaces while heating the plastic layers. Moreover, reaching a final elegant look using the plastic bags of foodlion and Trader Joes seems to be a challenging step toward delivering a nice looking finish.

In conclusion, the project has demonstrated the potential of plastic bags as a building material through heat lamination and provided insights into the optimal conditions for creating functional and aesthetically pleasing building components. The project has also highlighted the importance of finding innovative ways to repurpose plastic bags and contribute to sustainable development. By exploring the potential of plastic bags as a building material, the project has contributed to the development of sustainable architecture and interior design and inspired designers to create innovative and sustainable solutions.

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