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Posts by Michel Francois Haak

First postive molds are ready

 Today we collected a lot of molds. First of all we dug out the 4 high resolution prints at Architecture. These print were made with the plaster printer. These molds will be impregnated with candle grease tomorrow. This way they will be strong enough. When the printer started the job last Thursday, one of the print components was damaged. With a small repair we managed to fix it and thankfully it completed the job!

 

Also the high resolution cups were printed at the faculty of Industrial Design because the plastic had finally arrived. The result is really satisfying. The plastic is pretty strong, although one cup has a very little hole near a crack form the old glass. However when a negative mold out of plaster is made, the won’t be a problem.

First mold for porcelain has been made

Maaike Roozenburg did a great job in making a negative plaster mold around the cup which we printed in a plaster printer. This cup has been reinforced with candle grease and this works pretty good as you see. However, the cup has very complicated bulbs which meant Maaike had to spend a whole day in order to create this mold. With this particular mold, many porcelain cups can be made.

Museum Boijmans Van Beuningen glasswork has been scanned

Today we scanned the 17th century glass cups from Museum Boijmans Van Beuningen . One of the pieces has more holes then there is glass, so this cup will be hard to repair with the computer. However the material looks like new! The other pieces are very nice and also special. We also took some pictures from each glass with our own camera.

The plan is now to convert the files into STL files. However it seems like we will have to do this on our own, and this is a TOUGH job. We will try our best to make this project succesful but it will be very very hard this way…. We will try to print 4-5 glasses with the plastic 3D-printer before next thursday, but the plastic still hasn’t arrived…

 

Reinforcing a printed cup

Yesterday the printed cup was ready to be reinforced. This cup is now impregnated with candle-grease. This material gets into the plaster and fills up the brittle material. This way the cup will also be water resistant and the quality of the surface will be maintained.

In the pictures below you can see the candle greas melts in the pan. Also a few test parts made with the same 3D-printer are impregnated, the result was good so the cup was impregnated afterwards. The alternative was epoxy but this material is hard to order and very dangerous for your skin.

Maaike Roozenburg will test this cup coming thursday, the idea is to make a negative mold out of this cup. With this negative mold, a porcelain cup will be made.

Also, a few extra glasses will be printed before thursday, but only if everything will work out. There are some problems with the DICOM-scan files in which the glue between the different parts of glass is converted into a hole. When ir. Y. Song worked on these files it became clear a lot of the cracks were gone in order to fill up the holes.

Also some other news, the plastic material for the 3D plastic printer should arrive soon. When it arrives we can change the positive mold from 3D-Plaster to 3D-plastic which is stronger and more water resistant.

Coming thursday will be very important. We will scan the Museum Boijmans Van Beuningen glass-work and maybe a few other interesting things will happen…. We will keep you informed.

Testing begins

 

The last few days were quite hectic. Tuesday we printed four small molds with the 3d-plaster printer. These molds were finished with different materials so we could see how it would behave in the molding process with porcelain.
The first mold was impregnated with clear coat from a car-spray can (only the outside). The second one was impregnated completely with it, the third one was impregnated completely with clear nail paint and the fourth mold was original, we did nothing with it. Also, we had an extra piece of plaster (140 powder, impregnated with bathing salt), which we could use to test.

After the meeting on thursday, Maaike went to her studio and tested these molds. The results were quite disappointing. The result was that only the original mold and the 140 powder mold were absorbing water which is essential in the process. The others were to heavily impregnated and couldn’t absorb anything. Also the powder gets weak when it gets in touch with water.

Before last thursday, we also wanted to print a positive mold (identical to a glass) out of plastic on the liquid-plastic printer. This could then be used to make a plaster mold for making a lot of porcelain cups. But, bad news; The machine runned out of plastic-liquid and there is no reserve material. We were quite disappointed about this situation because we can not test this method now and we hope they get the material before we need to print the Museum Boijmans Van Beuningen glass in the week of 11 October. These positive molds will be used to create the plaster molds in which the 100+ serie of porcelain cups will be made.

After this, we decided to print the positive glass mold in the plaster printer. This is now printed and is drying over the weekend. After the weekend we will impregnate this cup with something like epoxy so it gets so strong, plaster can be poured all over it to make a negative mold out of it. We hope this method will work out. We will also try to find out how we can make a good negative mold out of the 3d-print plaster…

 

First real scan with old glass work.

Today we made a test scan of three glasses. These glasses are also from the 17th century Henkes collection so we could make a good test scan. We made this scan with the medical CT scanner (Siemens Somaton series) at the faculty of Civil Engineering. After making the scan we discussed what we could do next. We decided to make two types of molds of these scanned cups; a negative mold made by the 3d plaster-printer, and a positive mold made by a 3d-plastic printer. This way we can see if the print material is resistant to porcelain and how the result will look in porcelain.

On Thursday or Friday we have the results of the test with the plaster 3D print. If this works we can continue by making more scans and creating 3D prints. If the result is negative we have to look for another solution. We already brainstormed about coating the 3D print with different materials to see what works the best. First we have to see what the results of the test are before looking further.

Henkes collection

Plastic-positive molds:
The main plan is to create a 100% perfect plastic mold (positive), around this model a plaster mold can be made to produce a 100+ series of porcelain cups. The negative molds will be made out of 3D-plaster to test is porcelain can be molded directly in this material. This type of mold is more of a test and will only produce one porcelain cup.
This afternoon Sisko worked on the 3D files which rolled out of the CT-Scan. Tomorrow morning we will print one glass out of plastic. The plastic printer which will be used is a Objet Eden 260V. This machine works with liquid and UV light and produces pretty high quality surfaces.
This is a demonstration of the printer.
http://www.youtube.com/watch?v=LgPXY8ktbLE

After the plastic molds are made, Maaike Roozenburg will create plaster molds so the first porcelain cup can be molded. The negative molds will be filled directly with porcelain sludge.

3D-Plaster molds:
The negative plaster mold will be printed before Thursday. After a short conversation with Martijn Stellingwerff, we found out the plaster mold, directly out of the 3D-printer, is way to weak and will dissolve if it gets in touch with porcelain. Therefore the first 3d-plaster test molds will be impregnated with all sorts of materials.

Another plan didn’t make it today: Milling a negative mold out of a block of porcelain-mold-plaster. This could be a way to make a durable mold in which more then 100 cups could be made, but the milling machine can’t handle plaster; the powder damages all the components.

Glass photography:
When Boymans & van Beuningen will bring their precious glasswork next week for scanning, we will also photograph the glass cups. We can use these pictures for presenting the project. Today Michel used a beer-glass with a cracle effect. Afther all kinds of extra lightning, the pictures below shows lighting from below, this way only the glass and it’s cracks will be shown on the picture.



What’s next?

Before the next meeting on Thursday, the first molds will be ready for use! Sisko will place an extra blog later on about the 3D-STL files, in this blog Sisko will show a few very positive results.

Raw project planning

In order to make this project succesful, it is important to test this technique with a glass which is more or less identical to the Boymans en van Beuningen glaswork. Therefore we will scan a glass from the Delft archeological archive next monday. After this, the DICOM scan model will be converted into an STL file which can be used to 3d-print the negative mold including runners. When this mold is made, Maaike Roozenburg will make a porcelain model. After this proces it will be clear if 3d printing plaster is good enough for porcelain fabrication. The molds for the inside of the cups (inner mold) will be made out of plastic, so also for this part we need to do some work to get everything clear. If the 3d-print plaster is nog good enough for a negative shape mold, plan B is needed. In plan B, the glasswork will be directly printed in 3d as a replica. After this, a mold of real plaster will be made around this replica.

7 oktober will be the day for scanning the real glaswork. After this, time will be a determing factor because on the end of october, the porcelain cup has to be ready for the Delft science fair.

First introduction with CT-scanners

Yesterday we visited Ing. W. Verwaal at the faculty of Civil Engineering. Ing. W. Verwaal is a specialist in scanning all types of samples like soil, concrete, sandstone and asphalt. However, we will use the CT-scanners this time to scan the 17th century glasswork. Before we can do this we need to understand how the scanning process goes and what file/software we need to use. Ing. Verwaal showed us the scanners and showed us a model of an old glass which was scanned with the small scanner. This small scanner has a higher resolution than the big medical scanner but can’t be used for the real objects later on. That’s because of the fact that the objects needs to be glued on a rotating part for perfect scan results, ofcourse we can’t use glue on the museum pieces!
  We now have a DICOM file of the scanned example. Sisko will try to convert this file into a STL file, which we need. STL files are perfect for 3D-printing.
  Also, the other group members now will try to print a few examples on the 3D-printer. With these examples the behaviour of the plaster/glue can be tested. A possible big problem will be the use of porcelain sludge into a plaster mold made with a 3d printer. The sludge could dissolve the mold. The goal is to 3d print a negative of the glass object. This negative can be used directly as a mold for porcelain.
  It’s important in this project to do all the tests in advance, because the glass from Boymans & van Beuningen will be here at 6/7 oktober and the final product needs to be ready on October 26th (baking Porcelain will take 2 weeks).

 
 
 

Introduction post

On this blog, a project named ‘ Vindplaats Delft’ will be described from start to finish. The final goal will be to show ceramic drinking cups to the public at the final UNIC meeting, which is planned on May 2011 in Delft. These cups will be made with techniques used in rapid prototyping and pottery. The examples which will be used to develop the ceramic version will be glass cups which are unique and were made in the early 17th century. These archeological pieces are now part of the Boymans & van Beuningen collection.

 

 
Delft is more than 750 years old. The city owes its name to the world ‘delving’, digging the oldest canal, the Oude Delft (digged in 1100). As early as 1355 the city reached the size it would remain until the 19th century. The glass objects were found on locations like the Oude Delft and the Pieterstraat. Designer Maaike Roozenburg wants to use these pre-industrial cups with a rich history as a starting point for a new design, this way the old heritage can be used for daily use.

 

 
Maaike Roozenburg will cooperate with TU Delft students to create a low-tech product, with high-tech prototyping processes like CT-Scanning/3D scanning and 3D-printing. Eventually Maaike Roozenburg will use her porcelain expertise to create the final product in porcelain named ‘Vindplaats Delft’. This product will be supplied in a casket with information about the origin, create history and founding location.
This project will combine old crafts and high-tech technology together. It combines all the qualities which resemble Delft; rich history, traditional pottery and TU Delft knowledge and experience.

 

 

The group of TU Delft students are following the minor Advanced Prototyping, Vindplaats Delft is a project for ‘Augmenting prototypes’ under supervision of Ir. Jouke Verlinden. The group of five students consists of four Industrial Design students and one Architecture student.

 

 

Architecture bachelor

 
Sisko Roosenboom

 

 
Industrial Design bachelor
 
Elsa Noske
 
Astrid van Til
 
Rob Scharff
 
Michel Haak
 

 
This project is a cooperation between: Studio Maaike Roozenburg, Gemeente Delft, Working Group Delft ceramic City, TU Delft faculty of Industrial Design and Galerie Terra Delft.

 

 
This project is coupled to the UNIC congress(Urban Network for Innovation in Ceramics), a project of the EU.

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