PD L5
KSENIA SEMIROVA
11.2018
CAST IT
Designing and producing a surface-mounted light switch manufactured with molding technique. Module: Design Materials & Technology
Idea Development Inspiration Types of light switches
3 4 10
Types of feedback from light switch itself 12 Types of feedback from light switch Digital Prototype
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Experimenting with molding and casting
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Silicone & Plastic workshop
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Light switch master-model making 22 Master-model molding preparation 24 Types of utilized silicones
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Molding Master model
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Types of utilized epoxy resin
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Casting the form
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Casted light switch model. Final
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Visualization
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In the Interior
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Dimensions
62
Idea Development
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3
Manila
Venini Chandelier
Inspiration
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2
3
4 VENINI 1. 2. 3. 4. 5.
Venini Sconces, Paolo Venini, 1958 Siderale, Giorgio Vigna Sasso, Mimmo Rotella, 2003 Balloton, 2014 Abaco, Monica Guggisberg & Philip Baldwin, 1998
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Idea Development
Inspiration
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4
1
2
1. 2. 3. 4. 5.
Rain Drop Shell Crystal Shell Spear Cloud
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Idea Development
Vitrine Guerlain Idylle | 09.09
Inspiration
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Idea Development
Push-button
ALTERNATIVES
Types of light switches
Rotary
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Touch sensitive
Toggle
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1. 2. 3. 4.
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Switch by Orsteel light Garby by Fontini Sentido by Basalto Switch by Elo
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Idea Development
Types of feedback from light switch itself
textural interfaces
Visual
HIGHLIGHTING
HAPTICS TOUCH GRAFIK T light switch & dimmer by Lutron
Tactile Verbal
NATURAL TEXTURED MATERIALS
mostly for decoration
MECHANICAL SOUND
Arteor by Legrand
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Idea Development
Digital Prototype
THE IDEA The chandelier Manila by Venini became the main source of inspiration of the project. The main feature of the item is the air bubbles which are formed during the glassblowing. I tried to imagine the surface with this side effect inside out. This surface seems solid, at the same time it is lightweight. Also, it looks sophisticated and it is hard to understand what it is exactly. Thus, curiosity became the main feature of this light switch concept. 14
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Idea Development
Experimenting with molding and casting
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SILICONE MOULDING
Silicone & Plastic workshop
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Experimenting with molding and casting
Silicone & Plastic workshop
PLASTIC CASTING
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Experimenting with molding and casting
Light switch master-model making
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Experimenting with molding and casting
Master-model molding preparation
MAKING TWO PIECE MOLD
Separating component
Different sticks to make a lock
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Experimenting with molding and casting
Types of utilized silicones
SILIFORM WHITE Two-component silicone rubber mixture. Molded. Component ratio 100(A):3-5(B). Claimed cure time 8-12 hours.
TOOLDECOR T 20-18 Two-component silicone rubber mixture. Molded, cured at room temperature. Component ratio 100(A):5(B). Claimed cure time 12 hours.
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Experimenting with molding and casting
Molding Master model
Wet parts of the form were masked with masking tape. The form will be utilized as a sample for epoxy casting.
TEST 1. SILIFORM WHITE The required amount ≈220-250gr. Cure time was more than 12 hours. The form is half soft. Some external parts of the form were not cured even after 24 hours.
The gate was masked with gluegun to get the solid surface.
The quality of the master model texture could be claimed as satisfying. The formwork quality was low. Cast corners are rough. It is impossible to make second part of the form. 28
29
Experimenting with molding and casting
Molding Master model
Part of the texture was damaged due to premature extraction of the form. The form will be utilized as a sample for epoxy casting.
TEST 2. TOOLDECOR The required amount ≈220-250gr. Cure time was more than 12 hours. The form is very soft. Some external parts of the form were cured after 24 hours. It was extracted before full cured timed. It was not clear, that inner part of the form was not cured.
The gate was masked with gluegun to get the solid surface.
The quality of the master model texture could be claimed as very satisfying. The formwork quality was low. Cast corners are rough. It is impossible to make second part of the form. 30
31
Experimenting with molding and casting
Molding Master model
It was spent more time and afford to make better plasticine model for molding. The quality of f ramework was pretty good.
TEST 3. SILIFORM WHITE The required amount ≈220-250gr. Cure time was more than 12 hours. The form is half soft. In spite the different time and strength of mixing, some parts of the form were not cured even after 24 hours.
The gate was masked with gluegun to get the solid surface.
The quality of the master model texture could be claimed as more than satisfying. It is impossible to make second part of the form.
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Experimenting with molding and casting
Molding Master model
The parts were separated easily. It needs to clean some artif icial pieces of silicone.
TEST 4. TOOLDECOR. TWO SIDE FORM The required amount ≈220-250gr. per each part. Cure time was more than 12 hours. Finally, the successful result! One piece of the top part of the form has not dried enough, but it still can be utilized.
In spite all diff iculties during molding process, the form looks pretty good and potentially can be utilized to casting.
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Experimenting with molding and casting
Types of utilized epoxy resin
MG-EPOX-FLASH Two-component epoxy resin. Cured at room temperature. Component ratio 100(A):20(B). Claimed cure time 10 minutes.
MG-EPOX-ELASTIC Two-component epoxy resin. Cured at room temperature. Component ratio 100(A):50(B). Claimed cure time 24 hours.
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Experimenting with molding and casting
Casting the form
The texture is soft and touchable. It can be slightly stretched. It was a bit diff icult to get it out of form. Texture was not damaged due to pulling it out.
TEST 1. MG-EPOX-ELASTIC The required amount ≈10-15gr. Cure time was ≈12-16 hours. The resin originally transparent. Only green glitter was added. Sample made with Test 1 form Overall, the result of the texture is more than satisfying. It needs to connect the texture with the sensor.
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Experimenting with molding and casting
Casting the form
Extension piece was placed to put sensor part. The piece of polyethylene f ilm was the reason of smoke. The part placed in epoxy was completely dissolved.
TEST 2 & 3. MG-EPOXFLASH
The quality of the texture is rather poor. There are a lot of bubbles.
The required amount ≈20-30 gr.
Test 3. The place for sensor looks terrible.
Cure time was ≈30-40 minutes. The resin is originally bright dirty yellow. They were dyed to blue and red. There was a minor smoke during the solidif ication. The resin gets some heat.
Switch on/off sensor.
All samples made with Test 2 form.
Touch sensitive.
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Experimenting with molding and casting
Casting the form
Test 5. In this example, a single wire was placed in the cast. Unfortunately, the sensor has not turned on. The wire was not close enough to the top surface of the casting.
TEST 4 & 5. MG-EPOXFLASH. FINDING THE WAYS TO CONNECT SENSOR The required amount ≈20-30 gr. Cure time was ≈30-40 minutes. The resin is originally bright dirty yellow. It was dyed to green. All samples made with Test 1 form.
Test 4. Foil and wire were placed into cast.
The experiments with wire were not effective.
Sensor switch only with touching back side of the cast. Foil gave nice effect of reflection.
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Experimenting with molding and casting
Casting the form
The rivet that working perfectly with sensor wad placed into cast. The example fully provides the idea of sensitive textured light switch.
TEST 6. MG-EPOX-FLASH. FINDING THE WAYS TO CONNECT SENSOR The required amount ≈20-30 gr. Cure time was ≈30-40 minutes. The resin is originally bright dirty yellow. It was dyed to blue with glitter.
The side where supposed to be gate looks rough.
The samples made with Test 3 form.
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Experimenting with molding and casting
Casting the form
Unfortunately, the sensor has not turned on. The elastic part was too thick.
TEST 7. COMBINING MGEPOX-FLASH AND MGEPOX-ELASTIC. The required amount of Elastic resin ≈15-20 gr. The required amount of Flash resin ≈20 gr. Total cure time for both resins was ≈20 hours.
Overall, the idea to mix both resins was interesting and gave good result. The top surface is touchable, but the bottom is solid.
It was dyed with glitter and luminophore. All samples made with Test 2 form.
It was def initely better to put rivet into the f irst layer (elastic) of casting.
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Experimenting with molding and casting
Casting the form
Tests 7 & 8 were made simultaneously. Test 8 was f inished before this one. There was no room for extra resin in this form to make the surface solid f rom bottom side.
TEST 8. MG-EPOX-ELASTIC The required amount ≈40 gr. Cure time was ≈18 hours. It was dyed to blue with glitter and luminophore. The sample made with Test 3 form. The most successful experiment which shows well developed touchable texture that connected to the sensor and switches the light correctly.
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Experimenting with molding and casting
Casting the form
The test showed all rough and weak parts of the cast form which were caused by not well prepared master model. Also, the huge problem with air bubbles (which are the inspiration for the project) was revealed. It was noticed, that this type of epoxy, in general, is vulnerable to this problem.
TEST 9. MG-EPOX-FLASH The required amount ≈60 gr. Cure time was ≈30-40 minutes. The resin is originally bright dirty yellow. It was dyed to red. The resin gets some heat. The sample made with Test 4 two part form.
Overall, the experiment with two part form could be claimed as successful.
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Experimenting with molding and casting
Casted light switch model. Final
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Experimenting with molding and casting
Casted light switch model. Final
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Experimenting with molding and casting
Visualization
56 57
LED DINER CEILING LIGHT
In the Interior
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Visualization
In the Interior
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Visualization
Dimensions
SINGLE TOUCH
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MULTI TOUCH
Visualization
KSENIA SEMIROVA PD L5 | BHSAD
