Expeditions in Non-Metal by Maitreya Pathak

CEPT // BD2002 // Spring semester edition

Expeditions in Non-metal

Maitreya Pathak // UG180328 // Selected Works UG 180328 //

CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

2020

Expeditions in Non-Metal

Tables of contents

Wood Ceramics Plastics Other Materials UG 180328 //

CEPT // BD2002 // Spring semester edition

** Panton Chair by Verner Panton ***

Studio Brief This studio talks about the materials and overall specification of building products and its analysis through PDS product design specification, PRIMA Process mapping, and set of engineering drawings. This studio went through various materials starting from wood, ceramics, plastics, and other materials and its application in building products and systems.

** Material Rendering Explored**

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** image generated with Dimensiva and keyshot**

This studio talks about being sensitive towards the material and its exploration, specification and standards which play a very important role while designing and manufacturing. When you research about the material and get in depth knowledge including the suppliers and standard sizes or form the material is available in it reflects in the design process and overall efficiency of the material.

2020

Expeditions in Non-Metal

Bryan Nash Gill. “Woodcuts — Bryan Nash Gill.” Bryan Nash Gill. n.d. Web. 6 May 2020.

Wood Research, Prototyping, Space design, Drawings

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Wander // study

Sheesham Dalbergia sissoo

The first week we were told to look at our built environment and analyze wood as a building product material and further, we were told to do detailed research on any two species of wood where one must be hardwood and one must be a softwood.

Some products made out of sheesham like wood turned lamp and bowl combined with mango wood. which shows excellent workability of sheesham as a wood

Top: Sculpture carved out of a bark and makes use of excellent surface texture to add additional layers to the sculpture. Left: wood seen as a building material where used for the warmth and natural feel of the wood.

Sources

Primarily northern India, Nepal, and Pakistan, as well as Western Asia; also grown on plantations

Height

: 10-20 m

trunk diameter

: 0.6-1 m

Average Dried Weight

(770 kg/m3)

Janka Hardness

: (7,380 N)

Crushing Strength

: 55.5 MPa

Shrinkage

: Radial: 3.1%, Tangential: 5.3%, Volumetric: 8.4%, T/R Ratio: 1.8

Colour

Heartwood ranges from golden brown to a darker reddish brown. The pale, straw-colored sapwood is clearly demarcated from the heartwood, and is sometimes incorporated into finished products—possibly for reasons of economy rather than aesthetics.

Grain/Texture

Sissoo generally has a straight grain, though it can be interlocked— sometimes severely so. Texture is medium to coarse with a good natural luster.

End-Grain

Diffuse-porous; large to very large pores in no specific arrangement, few to very few; solitary and radial multiples of 2-3; gums and other heartwood deposits (reddish brown) common; narrow rays not visible without lens, normal to fairly close spacing; parenchyma vasicentric, winged, and confluent.

Decay

Sissoo has good decay resistance and is rated as durable to very durable.

Workability

Sissoo has good working characteristics, and responds well to nearly all machining operations (the exception being sections of wood with interlocked grain, which tend to tear out during surfacing). However, chalky deposits occasionally present in the wood can dull cutters quickly. Sissoo turns, glues, and finishes well.

Odor

Sissoo has a distinct scent that is characteristic of most rosewoods in the Dalbergia genus, though the scent is somewhat milder than other species.

Value

Sissoo is highly valued in India, where its price is on par with Teak. The tree itself tends to grow in a crooked fashion, so long, clear sections of lumber are seldom seen. One of the few Dalbergia species where certified sources are available.

Threatened

Although Sissoo is not evaluated on the IUCN Red List of Threatened Species, it is listed on CITES appendix II under the genus-wide restriction on all Dalbergia species—which also includes finished products made of the wood.

Common Uses

Veneer, plywood, musical instruments (percussion), furniture, flooring, boatbuilding, carving, and turned objects.

Wood board explored and 3D render tried for the composition. This has Oak, walnut and wild wood, white ash

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2020

Expeditions in Non-Metal

The box // This product was designed for personal use and aimed at enhancing beauty of the wood as a material and the grain selection and sanding is done in a manner that surface is smooth enough to intrigue the user. Triangular keys that reinforce the whole box are made out of darker hardwod. Takeaways from the this project were efficiency in material handling and got to know table saw is a practical advance wood working tool capable of precision in manufacturing but if used creatively can be used to make slots, rebates etc.

Process 3d models of box giving us the idea of the process and the exploration of lid and it mechanism

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Documentation of the box and showing the grain selection and surface finishing to intrigue the user, documented with objects to provide a sense of scale and its use in real life and purpose of the box.

Specification 2 10

Box is made for personal use, and is made out of Ghana teak panel which was 100mm wide and was 1 meter long and costed rupees 200. The box has no visible handles so to open it you need to push on the lid of the box from one end and due to the catch detail it behaves like a swith and opens.

150 160

2.5

80 75

ISOMETRIC VIEW (1:4)

PLAN

SECTION 2 2`

SECTION 1 1`

Takeaways Working with table saw to make rebates, grove, slots

HARDWARE 20

WOODEN TRIANGULAR KEY USED AS LOCKING KEY

SIDE ELEVATION`

FRONT ELEVATION

KEY

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EXPEDITION IN NON-METALS

T - GHANA TEAK WITH SURFACE FINISH AND DANISH OIL

DESK LAMP

K - KEY TO JOINT THE TWO MITER PLANES MADE WITH PINE V - PROPOSED VENEER DUE TO NON- SHRINKAGE

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Efficiency in using materials and dimensions accordingly

MAITREYA PATHAK SCALE : 1:3

GHANA TEAK SHEET 1 OF 1

Surface finishing using diffrent grades of sand-paper to achieve a certain finish.

2020

Expeditions in Non-Metal

Task Lamp This product was a building product designed as a minimal desk lamp which had an excellent luminance and resulted in ease in working and reduce strain on the eyes and allowed for accurate rendering of the colors. This lamp has a minimal footprint and can be clamped to side of desk where one of its adjustable arm as led strip with an acrylic diffuser

Led Housing Form Thinking

Detailing LED housing

Takeaways from the this project were wood-turning and to analyses which wood actually turns well with minimum grain tear, finishes well and is structurally strong to not let the bored hole to expand. While learning to turn wood i learned how to give fillets, chamfers and even the surface of the wood on a lathe.

Overall Form Development

Above: Experimentation with wood turning on pine wood and teak wood and process of giving fillets and grooves on lathe in CEPT workshop by myself. Top left : components of lamp

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Process sketches which shows the joinery brainstorming and the overall form formulation in terms of bracings and two arms.

Ø15 UPTO 375, Ø25 UPTO 210

Ø15 HOLE 90 FROM THE TOP EDGE

1 3

Ø25

Specification

TEAK WOOD DOWEL Ø25 (LIMSEED)

BRASS NUT

Task lamp was made out of Ghana teak and was actually wood turned into a cylinder with 25 diameter. Arm of the lamp was wood turned to be 15 diameter with slot for the led hosing. The major aspect of the lamp was the aesthetic and minimallook of the lamp.

490

DETAIL 1

450

580

540

WOODEN ADJUSTABLE CLAMP USING NUT BOLT

FRONT ELEVATION

SIDE ELEVATION

DETAIL 2

Ø8 SS304 METRIC THREAD SHAFT FOR ADJUSTABLE CLAMP BASE

Takeaways

Ø2

140

335 365

220 375

210 585

NUT TO LOCK AND FOR ADJUSTABLE CALMP

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PLAN

KEY A - ADJUSTABLE CLAMP B - Ø25 TEAK WOOD DOWEL WITH (LIMSEED) C - Ø15 UPTO 375, Ø25 UPTO 210 D - 5MM LED STRIP

HARDWARE Ø8 D-NUT LENGTH 100 USED IN BASE CLAMP Ø4 BRASS NUT LENGTH 25 5MM LED STRIP 12V

EXPEDITION IN NON-METALS DESK LAMP MAITREYA PATHAK SCALE 1:4

GHANA TEAK SHEET 1 OF 1

Wood turning Ghana teak to a acurate cylinder of 25 and 15. Selection of hardwood for wood turning. Exploration in woodturning for the fillets and radius given on a lathe.

2020

Expeditions in Non-Metal

Space design Specification My site is a reading centre in china and the interiors are done in wood and flooring is done in stone and specifically marble and is polished. The plan is organic and has large opening on its left curve. The opening has large glass panes which run full height of the space and is attached to the ceiling with help of patch fitting and some void made for the glass. The glass is curved according to the plan and is outsourced and custom made. The space has lot of natural light due to opening on its left and skylights on its edges which spread and increase the overall light. The flooring is done in marble and is polished to a specular nature to reflect the available light. Walls are acoustically treated with sound absorbing panels cladded on the walls which are white in colour which overall makes the space acoustically sound. The interiors follow earthly tones of brown and white. All the products and furniture are made from the same wood and have matte surface finish and duo wood is used for the contrast. This exercise made us visualize the space where the products were placed then understand and gauge its dimension with the relation to space. Based on a photo we needed to brainstorm several ways of achieving the specific joineries and form and then we were supposed to look at the efficiency, finish, and the materials and narrow down upon the joinery and inculcated a healthy habit of analyzing a product to its joineries and materials, as soon as we look at it.

Concept brainstorming about the shelf as a building product and its joineries and gauging its overall dimension

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Wooden Shelf // Specification

270

Wooden shelf made out of teak wood is a combination of linear elemnts both vertical and horizontal placed in the wooden space and locked with wooden dovel. Shelf top is made out of white ash and rests upon the wooden linear members.

170 370

170 220

190

260

1550

260 460

360

6 2450

FRONT VIEW

SIDE VIEW

SECTION 1 1`

170

400

460

2 1`

615 550

600

615 700

2450

TOP VIEW

Takeaways

DETAIL 1 SCALE 1:4

HARDWARE 4_ WOODEN DOWEL Ø7MM 5_ HIDDEN Ø10 BOLT WITH WALL CAPØ12 6_ TEAL WOODEN PANEL

KEY

EXPEDITION IN NON-METALS

1_ WOODEN MAHOGANY RAFTER 30X30 2_ WOODEN SHELF BASE ( WHITE ASH ) 3_ HORIZONTAL RAFTERS 30X30

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JAPANESE SHELF MAITREYA PATHAK SCALE 1:16

TEAK SHEET 1 OF 1

Brain-storming joineries, material, hardware by a photo Analysing a space and writing a detailed specification Drawing a engineering drawing out of a photograph

Wall Paneling //

Specification 1 (OLD JOINERY)

350

100

2 (NEW JOINERY)

A B

Performance: Discontinuous use Environment: : Load, vibration, shock, dust, sunlight, temperature difference, human touch Target cost: Depends on the wood used, plywood used usually costs rupees 2500/Indian rupees.

2400

3000

2020

Expeditions in Non-Metal

Competition: There is healthy competition in the market with constant innovation in this industry with companies like “Ecoste” Manufacture: Usually are mass produced with lengths 200, 270, 300cm and width between 30cm and 15cm but can be batch produced and can be produced individually for a custom look and exclusive look.

250

200 C

8000

FRONT ELEVATION

SECTION 1 1` 1

100

2000

100

2000

Standards: D5651 – 13Standard Test Method for Surface Bond Strength of Wood-Base Fiber and Particle Panel Materials D2898 - 10(2017) Standards it should have a specific fire rating, D2555 - 17a it should have specific janka hardness D7433 – 19 Standard Test Method for Measuring Surface Water Absorption of Overlaid Wood-Based Panels.

8000

TOP VIEW

167

HARDWARE

HARDWOOD USED _ CHERRY WOOD 2000X3000 (CUSTOM CUT)

A _ 7MM WOOD SCREW (SS304) MOUNTED WITH WALL PLUG 10MM (ABS)

MAHOGANY WOODEN RAFTER(100x50) x 2

C _10MM BOLT (SS304) WITH PLASTIC HOUSING 11MM (ABS)

CUSTOM VENEER ON TOP OF THE WOODEN PANELS

B _ Z CLIP 5MM THICK (MADE FROM CARBON STEEL , SERRATED EDGES)

150

WOOD

KEY

DETAIL 1

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DETAIL 2

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DETAIL 3

Materials: There is no standard for wall panelling usually is done with hard wood and special wood are used for special purposes. Quality: Product should not be warped; it should have good surface finishing with or without external finishes.

1900

NEW JOINERY

EXPEDITION IN NON-METALS

1 _ EXTENSION JOINT ( TONGUE AND GROOVE 100 FROM THE EDGE)

WALL PANELING

2 _OLD JOINERY SECURED USING (7 WOOD SCREW WITH 10 WALL PLUG) 3 _ NEW HARDWARE INTRODUCED ( Z-CLIP 5 THICK)

MAITREYA PATHAK SCALE 1:30

ROSE WOOD/TEAK SHEET 1 OF 1

Packaging: The product comes in custom made corrugated box and vinyl wrap which are then shipped are transported via road. Asthetics: Product is aesthetically pleasing and easy to assemble and mount with the given instruction.

Ceramics Research, Hands-On, Morbi, Drawings,

Throwing a vessle on a potters wheel at CEPT workshop**

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2020

Expeditions in Non-Metal

Material Study //

Silicon Carbide

Smart Glass

i n d u s t r i a l l y - p r o d u c e d

A lt e r at i o n i n p r o p e r t i e s o f g l a s s b a s e d o n t h e v o lta g e

Silicon carbide gained its extraordinary hardness thanks to the homopolar bond between the atoms of silicon and carbon. This strong bond also causes its high elasticity and extremely low thermal expansion.

Smart glass or switchable glass (also smart windows or switchable windows in those applications) is a glass or glazing whose light transmission properties are altered when voltage, light, or heat is applied. In general, the glass changes from transparent to translucent and vice versa, changing from letting light pass through to blocking some (or all) wavelengths of light and vice versa.

Properties of silicon carbide High heat resistance 1,350 / 1,800°C. Corrosion resistance. Extremely high hardness High strength in all temperature ranges (from – 100 °C to +1,800°C).

Suspended-particle devices Suspended

particles

chaos

when

charged

Excellent thermal conductivity. Low thermal expansion. Low specific density.

Types of silicon carbide Reaction Bonded Silicon Carbide RBSiC/SiSiC Sintered Silicone Carbide SSiC

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In suspended-particle devices (SPDs), a thin film laminate of rod-like nano-scale particles is suspended in a liquid and placed between two pieces of glass or plastic, or attached to one layer. When no voltage is applied, the suspended particles are randomly organized, thus blocking and absorbing light. When voltage is applied, the suspended particles align and let light pass. Varying the voltage of the film varies the orientation of the suspended particles, thereby regulating the tint of the glazing and the amount of light transmitted. SPDs can be manually or automatically “tuned” to precisely control the amount of light, glare and heat passing through.

Simpolo industry // morbi We had site visits to one of the leaders in tile and sanitaryware manufacturers; Simpolo group and visited their plants where the state of the art technology is incorporated in the manufacturing of tiles and got a detailed overview of the PRIMA in real-time and in front of the eyes. It was also helpful for enriching our knowledge about the innovations in the tile industry like, where you can digitally print a texture on to the face of a tile by capturing the photo of the native marbles and exotic stones using an extremely high-end camera mounted on a calibrated rig which takes 100-megapixel photographs and then these are sent to the printers which digitally print the image onto the face of the tiles. Textures were also translated on the face of the tiles where the depth of an emboss or ridge can be digitally controlled and translated. We also had a look at the sanitary ware industry and understood the details of manufacturing which are mentioned in the folio provided.

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CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

Clay products // hands-on Takeaways Ceramics was the material which made us learn what patience is, you start by mixing the Terracotta or stoneware powder with water, need the clay, wedge the clay on a canvas until your arms start hurting but then you try to center the clay on the wheel ignoring the fact few times; the clay lump would completely fly off the wheel, the socalled form we throw completely breaks off or, you just end up wedging and repeating the whole process again. Except for the wheel, we understood the slab technique where your three-Dimensional forms are basically clay planes of uniform thickness achieved by the slab roller that are attached by the serrated edge and use of slip. These are a few cups and vessels I tried making, major takeaways were using the wheel, centering the clay, trimming the edges and conditions of a thrown object.

All the shown product were made on wheel in CEPT workshop and documentation was done by me

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Space design Specification My space for ceramics was a modern bathroom with glass and ceramics products. The space has ceramic tile flooring as well as wall cladding. The space has a separate shower area which is divided by a glass sliding shower door which mounts on track which a on the ceiling. Beside the shower area is the main bathroom counter which is counter-top is granite and there is ceramic elongated sink and faucet lid which mounts on the counter top. Above the counter there is a circular mirror. Directly opposite to the counter there is standalone bath which is separated with rough textured tiles which have digitally printed wood texture. WC is also visible made out of ceramic and is beside the counter-top. The exercise made us identify different ceramic and glass materials in a space and the forms related to the specific material. We also learn how to write space specification and also analyze the building products in them.

Ceramic Elongated sink made from Slip casting

Base plate for faucet and mounting it to bathroom top.

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**Space render made with sketchup and V-Ray

Products Presented

2020

Expeditions in Non-Metal

Faucet lid //

Specification

Performance: : continuous use , housing and attachment of bathroom countertop faucet DETAIL A

Environment: : moisture, steam, dust, oil, human touch, shock,

114°

Target cost: This product costs 10000/Indian rupeess

Detail B

Competition: NA

15 4

Manufacture: They are usually batch produced according to the projects of various companies or is custom produced for a specific client.

50 70

Materials: Stoneware

SIDE VIEW

FRONT VIEW

Quality: Surface finishing, premium glazes, ringing sounds, proper edge treatment. Standards:N.A RUBBER GRIP PADS

35 70

Packaging: Unit comes in a printed box with foam beads and the installation guide and hardware in a plastic bag.

4 2 3

R18 110

130

15 25

110

15 50

Asthetics: Product is aesthetically pleasing and easy to assemble and mount with the given instruction.

10 25

130

PRIMA

260

PLAN

DETAIL A

DETAIL B

Proprietary process not revealed HARDWARE

KEY 1_ 7.5MM CASTED CERAMIC PLATE WITH CENTRAL HOLE Ø18

EXPEDITION IN NON-METALS

2_ EPOXY ARMOUR FOR SHOCK RESISTANCE AND CALIBRATED 180 LATERAL 3_ NOMINAL PLASTIC WASHER (PVC) @3 THICKNESS 4_ THREADED HOUSING FOR D-BOLT @Ø6

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FAUCET PLATE MAITREYA PATHAK SCALE 1:2

PORCALINE WITH GLAZE SHEET 1 OF 1

Elongated sink //

Specification 840 Ø70

Performance: discontinuous use , average wash cycle estimated around 5 min and done over 50 times in a normal working day.

Ø100

420

610

Environment: water, dust, heat, human touch, oil, friction, shock, steam

200

Target cost: This unit of elongated basin cost over 30,000/- indian rupees

R196

2 Ø35 COPPER PIPES

620(min)

864

400

Competition: There is an healthy consumer market in the industry with major companies involved in production of sanitaryware.

203

Materials: Casting and ceramic enamelling over the cast , painted on the underside of the basin.

Ø30

Quality: No surface abrasions ,mirror finish, ringing sound and use of premium quality hardware

PLAN

Standards: American ASME A112.19.1/CSA B45.2, ADA ,ICC/ANSI A117.1 ,CSA B651

SECTION 1 1`

116

170 135

305

R139 FRONT ELEVATION

Manufacture: They are usually mass produced and sold in large quantum for economies of scale.

SECTION 2 2`

Packaging: This comes in custom made corrugated box with bubble wrap and foam beads with all the hardware and installation guide packed in a plastic bag. Asthetics: Product is aesthetically pleasing and easy to assemble and mount with the given instruction.

PRIMA

Raw material and slip preperation

Ø71

Casting HARDWARE

Finishing Glaze Preperation and glazing

KEY 1_ CERAMIC RIB CREATED FOR SUPPORT 2_ COPPER U-TRAP Ø30 @ 18 GAUGE

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EXPEDITION IN NON-METALS BATHROOM SINK MAITREYA PATHAK SCALE 1:5

ENAMELED CAST IRON SHEET 1 OF 1

Quality assurance Packadge Dispatch

2020

Expeditions in Non-Metal

** Charles and Ray Eames designed in 1950

Plastics ** image generated with fusion 360 and keyshot

Research, Materials, Manufacturing Process, Product analysis, Engineering Drawings.

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Material research //

Cellulosics

Thermoset polyurethanes

hermoset polyurethanes are produced through the reaction of a multifunctional alcohol (polyol) plus an isocyanate. They combine similarly to condensation polymerization, except no water is given off, which is an advantage when making a finished product.

//Plastic from nature// hen John Wesley Hyatt developed celluloid back in 1868, he probably didnâ&#x20AC;&#x2122;t realize that he just developed the first family of engineering thermoplastics. They qualify as an engineering plastic because of their excellent impact strength, environmental stress, crack resistance Cellulosics are appreciated for their: easy processability; aesthetics; transparency; high gloss; pleasant feel; aptitude for colouring and decoration; low electrostatic build up; balance of fair mechanical properties and chemical resistance to oils, greases, and aliphatic hydrocarbons; possibilities of plasticization ; fair electrical insulating properties; fair performance/cost ratios; and food contact possibilities applications like glasses, hearing aids, and cosmetic cases, among others. Cellulosics, when modified with additives to improve processing, are easily formed with standard manufacturing techniques such as moulding and extrusion. Cellulosics were the first plastics to be made from a renewable resource, wood. Wood pulp is treated chemically to make alpha cellulose fibre. The fibre is then treated with acids and anhydrides to make cellulose esters. The finished esters are a fine powder that is compounded with plasticizers and other additives to make the cellulosic plastic compound.

Celluloid coatings are FDA aproved and used on medicins and cater to one of the historic use of celluloid that was camera reels.

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//Plastic from reaction//

Flexibility of urethane chemistry allows tailoring a wide range of properties to fit a diverse variety of applications. Isocyanates are reactive and toxic and must be handled with appropriate precautions. The liquid and reactive nature of the two urethane components can provide some excellent process opportunities. These properties make PU particularly suited to reaction injection moulding (RIM), a low pressure, fast process. This process can be used for making fairly large moulded parts such as auto bumpers. The material also works well in casting applications. bedding, packaging, vehicle seating, furniture, insulation and carpet padding. Rigid foams are used for construction, insulation, packaging and transportation.

Polyurethane products in various forms like soft core sound absorbtion panels to elastic gaskets and seals for industrial pipes and bushings to hard PU products.

2020

Expeditions in Non-Metal

Material Process //

Injection molding

//Ice cubes//

Injection molding is a cyclical, discrete process. The molding process itself consists of melting the plastic in an extruder much like the one we discussed previously, forcing the melted plastic into a mold, solidifying the part in the mold by cooling (a thermoplastic) or heating (a thermoset), opening the mold and removing the part or parts, closing the mold and repeating the cycle again. In the injection molding machine the screw and barrel function a little differently than in an extruder. The melt is achieved by the friction between the rotating screw and barrel and the external heat that is applied to the barrel through electrical resistance heaters, as in the extruder, but as the material is conveyed forward by the rotating screw, the screw is forced back in the barrel to make space to accommodate the melt. When adequate melt is prepared for the part to be made, the screw rotation is stopped and the screw is brought forward to push the melt into the mold. If you look at in step 1 the screw is fully withdrawn and a pool of melted plastic is in the front of the screw (shown in red). In step 2, the screw is pushed forward, forcing the melted plastic into the mold. If the part being made is thick, at this point the screw may be held forward under pressure for a time to make sure the gate area (the entrance area into the part) has cooled enough to

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prevent backflow of the melt. This is known as holding time. In step 3, the screw is rotated as a new melt pool is being prepared for the next cycle. While this is happening, the mold remains closed as the melted plastic is being cooled by water (usually) circulating through the mold to harden the part. In step 4, the screw is fully retracted and a melt pool is available to make the next part. At this point the mold is pulled open, the cooled part removed, the mold is reclosed and we return to step 1 to restart the process. Because of the back and forth action of the screw this is called a reciprocating screw process and the machine a reciprocating screw injection molding machine. As the process is restarted after every cycle, it is important to have good controls on all aspects of the machine function to insure a consistent melt quality and a consistent part.

Injection molded products and the versatile form of manufacturing

extrusion //Toothpaste//

Extrusion is a continuous process that will deliver a continuous stream of polymer melt that can be formed in a desired shape. A good analogy is that imagine the extrusion as pressing hard against a toothpaste tube and then the paste is forces to come out of the opening as a cylinder and as long yiu press the tube it will continue. The actual process is a little complex than just pressing against a tube, it starts with plastic pellets brought in through a feed hopper to a rotating screw which will convey the material forward through the barrel where the material is melted through shear, friction, and conductive heat using heat pods usually mounted along the barrel. Then it will be forced through the extrusion die that will give the melted material its desired shape. As the shape leaves the die it will be cooled using water bath, a cooling table or stream of air. The puller after the cooling step is a mechanical device which holds the

extruded profile. Extruded shapes are generally called profiles that includes bars, sheet, or any continuous shape, extrusion is a widely used process and can be used on any material that can flow including wide range of plastics. Most thermoplastics are used and some thermosets can be extruded. Based on the materials reaction to heat there are different types of extrusion possible like with materials with low heat tolerance like (pvc,cpvc) they are usually extruded using twin screw extrusion which heats the material more gently and some difficult , hard to flow materials such as (ptfe) are extruded using Ram extrusion where the rotating screw is replaced by an hydraulic ram.

Co Extruded pipe and wires are one of the most common examples where a substrate could be a copper wire is extruded with a polymeric coating

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CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

Product Analysis We had site visits to one of the leaders in tile and sanitaryware manufacturers; Simpolo group and visited their plants where the state of the art technology is incorporated in the manufacturing of tiles and got a detailed overview of the PRIMA in real-time and in front of the eyes. It was also helpful for enriching our knowledge about the innovations in the tile industry like, where you can digitally print a texture on to the face of a tile by capturing the photo of the native marbles and exotic stones using an extremely high-end camera mounted on a calibrated rig which takes 100-megapixel photographs and then these are sent to the printers which digitally print the image onto the face of the tiles. Textures were also translated on the face of the tiles where the depth of an emboss or ridge can be digitally controlled and translated. We also had a look at the sanitary ware industry and understood the details of manufacturing which are mentioned in the folio provided.

Plastic Hardware /// Engineering plastic ///

Plastic washers are often preferred over standard metal washers for several key reasons. First, plastic washers are known for having low surface friction, meaning theyâ&#x20AC;&#x2122;re less likely to deteriorate as quickly as their metal counterparts. Hardware includes Bushings,WashersRivets and threaded components.

Materials Nylon Polyethene (PE) Polytetrafluoroethylene (PTFE)

Nylon Washers And Hardware Nylon washers are hardware are famous are used in industrial setting due to some physical and chemical properties which are as follows : High Corrosion Resistance Impact Resistance Abrasion Resistance Fire Resistance (Melts, does not burn) High Tensile Strength Elastic Module

plasticizer Nylon 6/6 (High tensile, durable, creep resistance in high tempreature) Polycarbonate ( Heat resistance ) PVC ( Protection against natural elements like sunlight) Acetal ( Minimise water absorbtion )

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Space design specification The space I have chosen as a base matrix of analysis plastic building products is Briscola - Pizza Society in Milan, Italy. The built form is a curve linear single height space with strong leading lines leading you into the space. When you enter the space there is a cylindrical vantage point where the staff of the restaurant has all its needed fast-moving items such as incoming orders, plates, glasses and so on. The leading lines are established by ducts running along the length of the space and are power coated to a mute grey colour which is also the accent colour of the whole space. Space had epoxy flooring for heavy pedestrian mobility and ease of maintenance, Red and grey plastic emulsion paint for the interiors, Tabletop cladding with high-pressure laminates, polycarbonate globes mounted on the street lamps outside the store, PVC piping is done and I explored the PVC elbows. information and drawings of the above mentioned are given in the folio provided.

Products Presented Interim Wall Plate // PVC 90 Elbow Red interior with Mute Grey as Accent Colour aimed to achieve retro look .

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Cable gland

2020

Expeditions in Non-Metal

Intrim Wall plate // My first building product was an interim wall plate made out of polycarbonate which accepts the snap fit white switchboard fascia and is also accepted by the polypropylene wall plate. Major takeaways while drawing the product was measure drawing, and looking at the minimum tolerances while dealing with injection molding as a process like minimum fillet must be .5mm in injection molding and these must be taken into consideration while designing the product. I also was fascinated by a number of marks on the injection molded part near a detail where it translated to advance component in tool or mold making which is responsible for the corresponding detail, I also had a look at ejector pin marks which were of lesser surface quality and could be found throughout the product. An interesting aspect of this product was small cylindrical projections for a calibrated level fit and also doubling as ribbing to reinforce the product

60°

2.5 Ø2 Ø6

Ø2 DETAIL EDGE TAPEER AND THICKNESS OF THE MOLDING

E R4 90

SNAP FIT JOINERY WITH SUNK BED FOR CALIBRATED FIT

B 25

135°

Ø2

110 65

27.5

A_ Ø1 PROJECTION FOR CALIBRATION AND SUPPORT

EXPEDITION IN NON-METALS B_ Ø2 SNAP FIT THREADED JOINT WITH SUNK BED C_ SNAP FIT ACCEPTANCE VOID WITH .5 RIBBING E_ SUNK BED -1 FOR CALIBRATED LEVEL AND A RIB

CEPT // BD2002 // Spring semester edition

SNAP FIT ACCEPTANCE VOID WITH .5MM BRACING KEY

130

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POLY CARBONATE USED FOR FASCIA AND INTERMEDIATE PLATE

INTERMEDIATE BASE PLATE MAITREYA PATHAK PC SHEET 1 OF 1 SCALE 1:1

MATERIALS: INNDUSTRIAL GRADE POLYAMINE 6 FOR MAIN BODY // ELASTOMER BPDM, NITRILE FOR RUBBER PARTS

Cable Gland // PRESSURE NUT

17 R10 45°

17 R2

45° BODY

Cable gland is a an auxilarry component as a part of the led housing where it holds the cables in its place protected from any external environment and providing ingress protection against, dust moisture and fire. the cable glands are made out of cmponents and washers which are made out of industrial polymide and nitrile, EPDM elastomers.

9 5

DETAIL LOCK NUT MADE FROM POLYAMIDE 6 24 55

Ø24

14 28 120°

Take the Dome nut made out of industrial nylon 6 and feed the cables through it.

STANDARDS 1

17 38

PA 66 ( STANDARD FOR POLYAMIDES)

EN 60425 ( METRIC THREAD STANDARD) CAL 9005 ( COLOR )

Ø34 Ø17

DETAIL WAHER PADE OUT OF EBDM/ NITRILE ELASTOMER WASHER 17

Then lock the whole assembly usin hex lock nut.

120° 60°

Inspection

Then align the nitrile or PTFE rubber washer of .5mm thickness and then assemble the dome nut with the gland body.

DETAIL JUNCTION PRESSURE NUT THREAD WITH BODY THREADS

FULL ASSEMBLY OF CABLE GLAND

Ø32

Installation

DETAIL JUNCTION BODY WITH LOCKNUT WITH NITRILE/ EPDM WASHER

DETAIL TRAPEZOIDAL THREAD IN BODY AS WELL AS WASHERS

17 KEY

TOP VIEW

MATERIALS POLYAMIDE 6 EBDM / NITRILE ELASTOMER

EXPEDITION IN NON-METALS

A_PRESSURE CAP CABLE GLAND // PG 19 B_METRIC THREAD LENGTH VARIABLE ON SIZE MAITREYA PATHAK POLYAMIDE 6 C_LOCKNUT THREAD EN60425

SCALE 2:1

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CEPT // BD2002 // Spring semester edition

SHEET 1 OF 1

2020

Expeditions in Non-Metal

POLYVINYL CHLORIDE CHLORINATED POLYVINYL CHLORIDE UNPLASTISZED POLYVINYL CHLORIDE

PVC 90 elbow // 51

R36 R38

135°

136°

5 135°

R5 30 2

PVC elbows are a building product which was made to transform the linearity of the PVC pipes which are used to transport potable water as well as industrial slurry since the prominent use of vinyl chloride has been discovered, this building product has variants one with metric 60 thread which allows greater joint strength. This product is made out of injection molding and thensurface treated and edge treatments are given to them.

Installation Pipe Inspection Cutting Deburring Inspection cleaning Dry fit Depth of entry mark priming Application of solvent cement Joint assembly

UG 180328 //

CEPT // BD2002 // Spring semester edition

40 SOLID CORE DUE TO INJECTION MOLDING (5MM)

SECTION

EXTERNAL RIBBING FOR EXTRA STRENGTH (135°)

135°

88° 45 40 1.5

TOP VIEW

STANDARDS

INITIAL ACCEPTANCE 2° TAPER FOR EASY PENETRATION

F148 THREAD 60 SPECIFICATIONS ASTM D1785 SH 40 (PVC COMMERCIAL) ASTM F441 SH 40 (MANUFACTURING)

EXPEDITION IN NON-METALS 90° PVC ELBOW MAITREYA PATHAK SCALE 1:1

PVC// UPVC// CPVC SHEET 1 OF 1

Product Specification // Instalation

PVC 90 Elbow

Cable Gland

Performance:

Continious use

Performance:

Continious use

Environment:

Heat, vibration, oil, greese, Shock, Moisture, corosion, load, friction, heat, Sunlight,

Environment:

Electricity, dust, moisture, Fire, smoke,

Material:

PVC( Polyvinyl chloride) CPVC (chlorinated polyvinyl chloride) UV stabalized.

Material:

Technical details Dome nut Polyamide PA6 V-2 Sealing ring PolychloropreneNitrile rubber CR/NBR Gland body Polyamide PA6 V-2 Mounting nut Polyamide PA6 GF30 Moulded sealing ring Nitrile-Polytetrafluorethylene rubber NBR/PTFE

Quality:

The surface of the product should be free of scratches and sink marks in the thicker cross-section of then product. Their must we equal wall thickness throught the product.

Quality:

The components must be inspected free of any scratch marks, Scuffs, flashes and the components must be packed carefully and installation manuals should be provide.

Standards:

Pvc schedule 80 ASTM D 1784(12454) Dimensions ASTM d1785 type 1 grade 1 PVC 1120, Tensile strength ASTM D638 Flexural strength ASTM D790 Famablity rating ul94

Standards:

Polyamide PA6 GF30 Internal thread Pg as per DIN 40430, - Installation in clearance holes with dimensions according to EN 50262

Manufacturing:

Product is mass injectionmoulding.

Manufacturing:

Product is mass injectionmoulding.

Installation

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manufactured

Pipe Inspection Cutting Deburring Inspection cleaning Dry fit Depth of entry mark priming Application of solvent cement Joint assembly

CEPT // BD2002 // Spring semester edition

using

Installation

manufactured

using

Inspection Take the Dome nut made out of industrial nylon 6 and feed the cables through it then alling the nitrile or PTFE rubber washer of .5mm thickness and then assemble the dome nut with the gland body then lock the whole assembly usin hex lock nut.

2020

Expeditions in Non-Metal

** Cotton wool blend cloth render red *

Other Materials ** image generated with fusion 360 and keyshot

Research, Materials, Space design, specifications

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CEPT // BD2002 // Spring semester edition

Other materials Shifting from plastic , wood and Ceramic we looked at other building products material which are used in a built space. I explored the possibility of natural fibers in a built space and looked at Abaca and bamboo. I also looked at stone or specifically marble which popular nowadays in making of furniture

Bamboo Fibers Bamboo fibres used for interior decorating provide antibiosis, bacteriostatic and deodorization functions and protection against ultraviolet radiation. The sunâ&#x20AC;&#x2122;s ultraviolet radiation, heat and light are major contributors to the fading and deterioration of fabrics, carpets, furnishings, storefront displays and other interior items. Curtains made of bamboo fibre can absorb ultraviolet radiation in various wavelengths, thus they lessen the deterioration of fabrics and may help prevent the devastating effects of ultraviolet rays on the body

Uses of fibers in curtains block UV rays and other uses like partitions can be seen where f i b e r s a r e w e a v e d t o g e t h e r.

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CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

Agate // semi precicious stone

Agate is semi precious stone which is used only for its visual appearance and sense of luxury thus integrated with some of the building products it enhances the space visually but its not functional. It had dark bands towards the edge of these rock formations and have optical quality and nature.

Visually striking building product which symbolize luxury and power

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CEPT // BD2002 // Spring semester edition

Marble //

Marsotto Edizioni, studio nendo

Space Design // Detailed modular shelters, intensive care, deployable, shelter

The need of the hour is time and responsiveness towards the pandemic we as a world are facing, this pandemic has impacted the whole world and healthcare industry is the major workhorse right now. In this age of recession and this lockdown, we should focus on two major things we have been talking about in our design process, Efficiency, and effectiveness. We as creative professionals can contribute to this current situation by our inputs on various levels such as product design, graphic design, architecture.

What is Adapt ? Adapt as its name suggests is a modular shelter that can be transformed according to the needs and has the potential to interact with individuals to adapt units and form a larger community as a whole. Adapt is a fast-moving commodity that has its focus on catering to the needs of the users who are in need. thus adapt was designed to be deployable, fully furnished, and with modular ability. Adapt aims at using medical plastics and the ability of rapid prototyping associated with plastics, adapt also uses Hardwood for its structural members like the central post and rafters.

Design Specification Adapt has its footprint as 10meters x 15 meters which is a large area and also can accommodate a family or number of peoples, you can visualize adapt as a cuboid with two of its longer edges truncated at 30 degrees for the accommodation of the acrylic skylight with crystal glassing to ut the amount of radiation and also is installed with bamboo louvers to cut the amount of UV as the shelter is oriented facing north. Flooring plays a very important role in these shelters as we know the virus is prone to settle on the ground needs to be non-porous for the sanitization and should not lose its dimensional stability and physical properties after repeated sterilization. Adapt also has developed a building product which is the Adapted (adapt bed/bedding) which is a modular bed which comes in various sizes and interacts with it built space like a mounted nebulizer, and all the electronics housed inside the bed, in case of code red the bed transforms into an independent stretch which is cable to need the patient as an individual unit. Space also has a dedicated wet area and pantry, it has a sprinkler system mounted at the +150mm which sterilizes the floor with a certain radius periodically. Adapt also has transition areas where outside health workers come inside the shelter space is provided with air curtains, UV, and scrub sinks for the safety of everybody so the risk of exposure is eliminated. Being sensitive about the affected patients is also an important feature I am proposing a full transparent corridor which eliminates the sense of being traped and he is aware of the passage of time through visual stimulus they gain from the passage, this can be made out of inflatable material, acrylic. The partition will be an important building product that plays a major role in space making.

UG 180328 //

CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

Space Design Specification 10x15 meters of the footprint is divided into various sectors based on the activities, shelter id due north thus receives ample amount of natural light and also receives the early daylight through the skylight on its one plane and to keep out the direct sunlight/ harsh light at noon horizontal lovers or light shelf made from bamboo is used so the light can be penetrated deeper into the room and gets diffused. We enter the space in the transition area which is followed by the wet area and is placed at oe on the plane due to the incorporation of exhaust systems and drainage. then besides the transition, there is the main housing of the patient where the bed and all the other necessities come which is slightly raised to+150 to provide for space making and also incorporated with slopes for the mobility of bed in case of code red. The activity area is the user can sit back relax, or can set up his workstation or any task because of the ample daylight acts as task light where he can work. the utility area stretches from one end of the room to another along the shorter side which included the pantry and the storage needed for the user as well his treatment this also houses a scrub sink of standard size depending upon the number of persons living. the green patch is what I call the social patch where the user interacts with the nature the passage is fully transparent with the ambient noise of wind and air is simulated as what iris outside, the temperature difference can be felt by the user to make different of another space more prominent.

Product// Specification (scope) Flooring// vinyl flooring, tiles (Material specification, costing*, Alternatives, specified material and why? standards Sprinklers// plastic product (material specification, overall volume, auxiliary accessory, metal embedded parts, standards. Skylight// Glass vs acrylic (material specification, PC vs Acrylic, size, Auxiliary components) Bamboo lovers// bamboo vs bamboo fibres (material specification, raw material, sizes, curtain vs louvers) Scrub sink//Plastic vs ceramic (material specification, overall size, MOC, standards) Bed//Guardrails, Headboard (material specification, top manufacturers, standards, MOC) Partition// plastic vs fabric (material specification, size, standards, MOC) Standalone storage system//plastic vs wood (specification, modularity, size, MOC) Tent canvas FRP portable bathroom unit

*MOC- Material Of Choice , where I discuss and draw parallels between the substitute material and why i chose the particular material for the manufacturing.

UG 180328 //

CEPT // BD2002 // Spring semester edition

space planning done with colour blocking

Product Specification //

esk Product description As it was seen in the space design description the space has a dedicated workspace which has to be modular as well as moveable . the desk is a medium sitting desk of height 740 and is made from engineered wood which is backed by a industrial grade laminate which will prevent the ingress and maintain the surface as a smooth working place.

Specifications Standard table top height – 740mm (including table top thickness of 25mm) (b) Work surface shall be 1500mm x 1500mm made up of 25mm thick laminated plain particle board interior grade conforming to IS: 3087-1985 (or Latest if any) with PVC lipping/edge binding 2mm thick. (c) The top shall be factory-made, laminated with laminate of 1mm thickness of approved shade as per IS : 2046-1995. (d) Bottom shall have a backing laminate of minimum 0.6mm thickness. (e) The front edge of work surface shall be provided with machine pressed 2mm thick PVC lipping/edge binding. (f) Non-working edges of the work surface shall be provided with machine pressed 0.5mm thick PVC lipping/edge binding. (g) The cable manager on the work surface shall be of flexible plastic component for easy and safe passage of wires. (h) Plastic keyboard pullout tray made up of durable ABS (Acrylonitrile Butadiene Styrene) material shall be on sliding telescopic channels. ISO 2580-1:2002 Plastics — Acrylonitrile-butadiene-styrene (ABS) moulding and extrusion materials — Part 1: Designation system and basis for specifications Nylon casters are also paired with the desk.

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CEPT // BD2002 // Spring semester edition

Flooring Product description Since it’s introduction polyvinylchloride (PVC) or ‘Vinyl’ sheet has been one of the principal flooring materials used in healthcare facilities. It is a durable, resilient and impervious sheet material providing an economic ‘polish free’ low maintenance and hygienic solution, previously only achieved by using hard surfaces such as terrazzo and tiling PVC is a polymeric thermoplastic material with vinyl chloride polymers/copolymers acting as a binder with plasticizers, stabilizers, fillers and pigments to form a stable compound. Vinyl sheet is generally available in 2 mm thick, 2000 mm wide rolls. Other specialised products with thicknesses up to 4 mm are available

Why Pvc The widespread and accepted use of vinyl sheet flooring in the healthcare environment is due to the following properties: long usable life with maintained appearance resistance to damage, with ease of repair impervious to water, oil and grease ease of cleaning and maintenance assists infection control slip resistance cost efficiency

Specifications BS EN 649, 650 and 651 covering different vinyl floor coverings. BS EN 685 provides the following ‘Use Area Classification’ system for resilient floor coverings: Class 23 Domestic Class 34 Commercial Class 43 Industrial. ubbases should have a smooth flat surface free from imperfections that will show through the floor covering as raised surfaces will wear rapidly, damage the installation and constitute a safety hazard. Subbases should be free from moisture and hydrostatic pressure. Requirements are clearly defined in AS 1884 and in most manufacturers’ instruction ISO 14001 Environmental Systems Accreditation

2020

Expeditions in Non-Metal

Product description For a workstation you need a proper seating arrangment, classic office chair has been in us since history has evolved into many forms with all sorts of linear as well as composite form. but i am specifying the classic revolving chaie made out of nylon and the frame structure made out of ss and powder coated

Cha

Medium back rest ergonomically designed revolving chairs. (b) The chair should have a hydraulic gas-lift (As per DIN 4550 2004-12 - Klass 3) for seat height adjustment. (c) Fabric shall be fire retardant (As per ASTM D 1230-1994, IS: 11871-1986). (d) The seat and back should be foam-cushioned and back should have ABS cover. (e) The chair base should be of nylon material (BIFMA 5.1) for strength with nylon wheels (As per ANSI/BIFMA X5.1-2002) Specification of powder coating Powder coating shall be with Epoxy powder of a standard shade or as required. (b) The specific gravity of powder should be such that it gives DFT (Dry Film Thickness) of 50 – 60 micron. (c) It should withstand salt spray test of not less than 1000 hrs as per ASTM- B- 117. (d) SCRATCH HARDNESS TEST as per DIN 53153 shall be conducted and results should be such that no scratch shall show bare metal with a load of 3 kgs. (e) The following seven step phosphating process treatment shall be conducted before powder coating. (i) Hot water rinse (ii) Knock of Degreasing (iii) De-rusting (iv) Cold water rinse (v) Activation (vi) Phosphating (vii) Passivation. Fabric : Composition, Surface – 100% Polyamide, Substrate - 65 % (polyester) 35% (cotton) Fabric shall have quality of user friendly for maintain cleanliness by simple vacuuming Handle armrest : The armrest shall be gas-assisted injection molded from black polypropylene. Seat & Back Assembly : The seat and back shall be made of PU foam of density 45 ± 2 Kg/ m3 upholstered with changeable fabric upholstery covers (as per requirement). Back Size: 480 mm. (W) X 550 mm (H) Approx. Seat Size: 480 mm (W) X 550 mm. (D) Approx Base : Five prong made of black color Nylon , wheels and pneumatic up & down with one point locking mechanism reinforced with glass fibers.

UG 180328 //

CEPT // BD2002 // Spring semester edition

* * i m a g e g e n e r a t e d w i t h S k e t c h u p Wa re h o u s e a n d k e y s h o t

Specifications

Site Visits India wood 2020 The site visit to India wood 2020 international exhibition was an eye opener where we countless stalls and installation and which gave us to the modern in innovation and machinery used for manufacturing anything. We saw the matrix of machinery under one space where we can practically manufacture anything, like from two, three and five axis CNC milling machine used to make sculptures and wood turnings to Wood veneer manufacturing. We also saw the machineries and gave us a offline catalogue where i can set up a workshop at my place in the future from Glue to power tools and catalogue of these.

The catalogue and the documents reveal only vast amount of knowledge and innovations we saw and we added to our knowledge and also vast amount of machineries we saw needed in a workshop.

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CEPT // BD2002 // Spring semester edition

2020

Expeditions in Non-Metal

Refrences Wood Divider__ Wood cuts Bryan Nash Gill. “Woodcuts — Bryan Nash Gill.” Bryan Nash Gill. n.d. Web. 6 May 2020. <http://www.bryannashgill.com/woodcuts> Wood Products sheesham - “sheesham products - Google Search.” Google.co.in. n.d. Web. 6 May Reading center china__ World Architecture Community. “Waterfrom Design creates peaceful interior with wooden furnitures for tea community center in China.” Silicon carbide products__ “silicon carbide products - Google Search.” Google.com. n.d. Web. 6 May 2020. Smart Glass __ ndiamart.com. “Switchable Smart Glass.” indiamart.com. n.d. Web. 6 May 2020. Smart glass diode__ “smart glass - Google Search.” Google.com. n.d. Web. 6 May 2020. Film coating__ “An introduction to pharmaceutical film coatings.” Pharma Excipients. 31 Oct. 2018. Web. 6 May 2020. Kodak celluloid__ ”celluloid - Google Search.” Google.com. n.d. Web. 6 May 2020. <https://www.google.com/search? Polyurathane__ “polyurethane products - Google Search.” Google.com. n.d. Web. 6 May 2020. Injection moulding_ “The outline of injection molding.” Polyplastics.com. n.d. Web. 6 May 2020. Legos photo__ Take Your LEGO® Skills to New Heights with These Tips from Real Life LEGO Masters.” Fatherly. 27 Jan. 2020. Web. 6 May 2020. Extrusion__ OpenLearn. “Manufacturing.” OpenLearn. n.d. Web. 6 May 2020. <https://www.open.edu/openlearn/science-maths-technology/design-innovation/manufacturing/content-section-0> Briscola pizza__ Studio Fabio Novembre. “Studio Fabio Novembre, Jacopo Spilimbergo · Briscola - Pizza Society.” Divisare. n.d. Web. 6 May 2020. <https://divisare.com/projects/395126-studio-fabio-novembre-jacopo-spilimbergo-briscola-pizza-society Bamboo curtains__ indiamart.com. “Window Bamboo Curtains.” indiamart.com. n.d. Web. 6 May 2020. Bamboo partitions__ ”bamboo partitions - Google Search.” Google.com. n.d. Web. 6 May 2020. Marble__ Studio nendo 2016 work by Marsotto Edizioni, studio nendo

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CEPT // BD2002 // Spring semester edition

UG 180328 //

CEPT // BD2002 // Spring semester edition

Expeditions in Non-Metal

Articles inside

Expeditions in Non-Metal