Watch how we made them!

http://www.youtube.com/watch?v=3Ujn202cD0Q

Weaving pattern for seat

Weaving pattern for side

Stool 1

^Ta da!

^Zoe's hand

^The finished seat

^Beginning to weave the seat

^Finally got the stool off the mold

^haha

^Taking the mold apart

^Tape over two tan spools and one blue spool

^After the first and second spools of tan hemp were woven

^

^

^Beginning to weave the first spool of hemp

^Finished mold

^Team Suzan!

^Putting the plastic around the mold

^Building the smaller mold

http://www.youtube.com/watch?v=ENa1ISS4i_8

http://myweb.cableone.net/bcanderson/Boatz/Vacuum/Vacuum.html

A pretty comprehensive explanation of how to make a homemade vacuum bag process and how to use it with fiberglass and resin.

Rotational Molding

University for the Creative Arts DIY Rotational Molding 

London Design Week 2009: Andrew Duffy of Myfirst from Core77 on Vimeo.

Cheapo Vacuum Formers

Home Made Vacuum Former

$5 Vacuum Former

Vacuum forming for UAV aircraft fuselage

Sustainable product design reading summery

This articles talks about the ways designers can create products that are more sustainable and safer for us and the environment. A product must have "total beauty" meaning that not only is the product aesthetically pleasing, but it is also good for people, profits, and the planet. There are 5 general solutions that help create a product that has total beauty. Cyclic, Solar, Safe, Efficient, and Social.

Cyclic

This is basically referring to how well the products stays in a loop, whether that be a organic loop, or a man-made closed loop. If the product is made from compostable organic materials the product can go through its life-cycle then be decomposed and later introduced into a new life-cycle. This is also referred to as "Cradle-to-Cradle". If a product is to be part of a man-made closed loop, then it must be made from materials that can be continuously recycled and kept in the loop. This can be done by recycling, re-using, or remanufacturing.

Solar

This means that when a product is manufactured and in use should only use energy that is renewable and safe. There are many types of energy sources that meet the renewable and safe criteria other than just solar power. Although most of their origins are solar power, they create other ways of harnessing and using energy that is safe. Photovoltaics harness the sun's energy directly using solar panels. Biofuels are also a very important form of energy. Biodiesel is made from rapeseed oil and can be used in a normal diesel engine with minor modifications. Although is gives of CO2 when burnt, the CO2 is part of the current carbon cycle. Ocean waves are also a very useful but overlooked form of energy. Currently Scotland is using the ocean to create electrical power and OSU has been doing research in this area. Muscle power is always an option as well, it just means that people have to be less lazy.

Safe

This can be a very general term but in this context it means that a product "cannot chemical or physically disrupt people or other life". If products are not designed with a specific takeback, full re-use, or cyclical system, then it is considered a toxic release and is not safe. This toxic release will affect air, water, land and space.

Efficient

There has been great strides in finding new ways of create more efficient products. This can mean that the product is manufactured using less energy, which translates to saving money and time, or that the product has been creatively designed so that it has a longer use. If you can use fewer materials, have products that are multi-functional, and create a system of sharing and renting between people, you can create a more efficient product.

Social

We can't forget about the people that are actually making the products. Every designer should know where their product is being manufactured and by whom, and that the manufacturers abide by the laws and regulations that treat workers fairly. The principles of the SA8000 standard strive to create a safer and fairer work environment for the employees of the company. This includes safe and healthy work environment, proper compensation, allowing the workers to still attend school, not forcing them to work long hours, and overall respect for those working.

This reading also goes into rating certain materials and how much impact they have. This rough system created by the author uses a "UglyPoint System", (1, 5, 15, and 50) to rate certain materials, low (1) include materials such as bioplastics and ceramics while Very High(50) include things such as batteries and metals such as lead and Nickel.

The reading also goes into some depth about noteworthy materials, types, and trends. It does include a warning that simply changing the material of a product doesn't necessarily make the product safer or better. All aspects of the product should be considered while being designed.

Wrapping Carbon Fiber

For being carbon fiber, this sample seems pretty brittle. First off, we made the mistake of not spraying or coating the PVC with anything, so the carbon fiber fused to that and had to be chipped off. Secondly, the strands seemed very easy to break, especially where there were only 1 or 2. In the middle where there was the most buildup, it seemed much stronger, but for the weight and the thickness of material, the woven fibers seem to be providing a better structural solution.

Foam Core

After watching a Nova show about making stronger materials, I was inspired to create a super strong foam cylinder wrapped in a strong, resin-soaked cloth. My first attempt involved spraying foam in between two pieces of PVC pipe to create a nice, even wall thickness and a perfectly cylindrical outside and inner core.

I wrapped both pipes in thin plastic to keep the foam from sticking to the PVC. As you can see, whatever chemical reaction was supposed to happen, didn't. 

Unfortunately that didn't work. I'm not sure if there wasn't enough air, or the can wasn't shaken well enough, but very little of the foam actually expanded like it was supposed to.

My next attempt involved creating a hallow cylinder out of fabric and filling that with foam. It seemed to work, but only kinda. Firstly, I didn't have quite enough foam, so the cloth wasn't filled all the way. Secondly, because there's a seam where the two halves of the cylinder come together, that point is very weak. Thirdly, it's really ugly looking and way too big around. I was hoping to get a taller, thinner cylinder, rather than a short, fat one.

More Materials Tests

Metal Screen: Not at all effective

Metal Shavings: We drained as much of the resin off as possible to see if they have any strength on their own. They don't really. The metal shavings flake right off.

Fishing Line: Pulls apart really easily. But it is very springy from side to side

Cheesecloth wrapped Metal Screen: Very interesting, it's a lot squishier side to side than just regular cheesecloth, but the metal prevents it from breaking.

Cheesecloth w/ EcoPoxy VS. w/ Toxic Resin: Vertical pressure properties seem about the same as with the toxic resin. Sideways pressure is close, but it seems a little more springy. Also, it's clear so it has a much more beautiful finish

Cheesecloth w/ Toxic Resin (small): Super awesome. Can hold 200+ pounds vertically without any sign of stress.

Dissolvable Paper: Snaps easily, Probably won't dissolve after being soaked in resin.

Foam: Surprising amount of strength for such a thin sample.

Metal Shavings wrapped in Cheesecloth: Seems pretty strong, though still slightly flexible. Tried using the smallest amount of cheesecloth possible, but it was too little and the core wasn't completely surrounded; bad sample.

Treading Machine

Our design is as simple as possible. A bent wire ensures the fibers reach the bottom. It's held in place by a two strips of wood, which the fiber then passes between to remove excess resin. The whole thing is held onto the mixing bucket with a rubber band so it can be easily moved from one to another. We used the mixing bucket to reduce the number of containers used in the process.

Reading Summary:

Beautiful looking products usually have underlying ugliness. There is the same amount of atoms on the planet, but humans have turned a lot of them into useless molecules.

Products should be designed to be upcycled. Downcycling is better than a landfill, but it is not cyclical. It is important to research products completely. A “plant based” product can be extremely toxic and bad for the environment, although probably better than the synthetic alternative.

It is possible to burn fossil fuels safely, but not practical or an efficient use of time. Fossil fuels enabled our current world, but it is time to move on to something else. Biofuels do emit carbon, but it does not add to the carbon cycle like fossil fuels do. Potential energy sources such as wave power have huge amounts of energy contained in them that should be explored.

Embodied energy is a big part of a product’s impact. Even products that use no power during its lifetime can have a big impact on the environment from production, shipping, etc.

Dilution is not good. We do not know the effects of many chemicals that we use today. The idea that it is safe unless proven dangerous is not smart. We should only disperse of chemicals in the world if it benefits where it is being dumped.

Tracing materials and products back to their origins can provide a lot of information. Many times natural materials and processes such as fishing, hunting, etc are harmful to the surrounding environment. Although not necessarily practical, it is best to buy products that were produced locally and to thoroughly research the methods used in manufacture. Since tuna fishing cannot be done with nets anymore, boats use lines and bait. Albatross try to eat the bait and are dragged underwater and killed. Side effects like this are detrimental to species and can be easily avoided.

Electricity produces no emissions during use, but producing electricity uses a lot of fossil fuels. Once solar and other renewable systems of energy are in place, electricity will be pretty clean.

There is a lot of waste in production, which makes no sense because companies are throwing away money. It would be in their favor to research efficient and green production methods.

Clever approaches to upgrading and repairing products can extend the life of products and reduce waste. Engineering a product so that it is easy to upgrade the interior components or so that the exterior skin can be changed means that people will not throw away old products when newer models are introduced.

One college had a big oak beam as a key structural component. The architects planted an oak tree when the building was constructed, however, so when it eventually rotted, there was an oak tree from which a new beam could be milled.

Bamboo:

Properties:

-Very “Green”; Fast growing and growing bamboo creates jobs

-100% biodegradable

-No chemical additives

-Does not irritate skin

-Hypoallergenic

-Highly absorbent

-High Tensile Strength

-Flexibility makes it great for reinforcing brittle materials

-Has recently begun being used in designer clothes because of its comfort, breathability, hygenic properties and durability.

Suppliers:

-Shanghai Tenbro – Main producer

-Bamboosa - distributor

Geography:

-Bamboo is found throughout much of the world, but is commonly found and produced in Southeastern China

-Can grow is a wide variety of temperatures and weather.

Tyvek (Spunbond Olefin Fiber):

Properties:

-Very strong, difficult to tear

-Easy to cut

-Water vapor can pass though Tyvek, but not liquid water

-Lightweight

-Flame resistant

-Not usually accepted with municipal recycling programs, but DuPont has a special recycling program

-

Suppliers:

-Produced solely and trademarked by DuPont

Geography:

-Manufactred in Richmond Virginia and Contern, Luxembourg.

Plaster Of Paris (Gypsum Plaster)

Properties

-Material based on calcium sulphate hemihydrate

-Dries solid, but is soft and easily manipulated

-Not good for load bearing

-Chemical reactions involved in producing and mixing plaster ca create a lot of heat and can be very dangerous

-Irritant when inhaled

-Some versions can have asbestos traces

-Possibly carcinogenic

-Hard to clean up and recycle

Suppliers:

- Available at any hardware or craft store

-

Geography:

-Manufactured throughout the world

-Commercial quantities of gypsum are found in the cities of Araripina and Grajau, BraZIL, Pakistan, Jamaica, Iran (world's second largest producer), Thailand, Spain, (the main producer in Europe), Germany, Italy, England, Ireland, Canada, New York, Michigan, Indiana, Texas, Iowa, Kansas, Oklahoma, Arizona, New Mexico, Colorado, Utah, Arkansas, and Nevada. s

-

Gelatin Binders:

Properties:

- Gelatin Binder Prepared from Gelatin and Colloidal Silica/Polymer Latex Composite Particles were stronger and less likely to fracture than other commonly used binders

-Highly adhesive

-Electrochemically stable

-

Suppliers:

- Still very experimental and is being developed by various companies and institutions around the world such as the military and battery producers (because of its electrochemical properties)

Geography:

- Is being developed around the world, mainly Japan and the United States

-

Pasta:

Properties:

-Can be molded when recently cooked, but dries stiff

-Brittle

-Various sizes, shapes and ingredients with various properties

-Low tensile strength

Producers:

-Thousands, such as Barilla

-Pasta makers are sold commercially ranging in price from around $25 to $200

-

Geography:

-National dish of Italy

-Found everywhere in the world

-

“Cradle To Cradle” reading summary:

Discusses the industrial revolution and the flaws in the way we thought about the world and resources at the time. New technology and rapid production led to new technologies for transporting, etc creating pollution and using fossil fuels. Changed cities and the world permanently to fit this new way of production. People chased the instant gratification and ignored that these resources are not limitless or replenishing. Our modern industries are still functioning how they did when we had this idea that resources were replenishing, which doesn’t make sense.

“Cradle to grave” is domination manufacturing today. The product itself contains on average 5% of the raw materials involved in production/delivery. Nature’s “industry” has a constantly replenishing energy source (sun), while human manufacturing does not. Products and houses are made without consideration for nature’s beneficial aspects such as the sun, shade, etc. Soon business will have to change their methods, but by then we will have destroyed the earth.

Economic prosperity is measured only by money, not other important factors. Oil spills, car accidents, illnesses and toxic spills raise GDP, etc. Tons of products off-gas poisonous chemicals. Substances are banned in US, but if they come from another country they can be used in US. Bad indoor air quality and chemicals leeching into skin. More than half of household items release seven toxic chemicals knows to cause cancer at a rate that would be alarming at a superfund site. Chemicals are everywhere and there are too many people to go back to completely natural products, so we have a problem.

Polyox

This is a water soluble plastic that is used in pharmaceuticals, like the dissolving capsules for pills. This combined with a water soluble fiber could make a composite that is totally dissolvable in water. Further research will be done, but so far it looks like the polyox and the water soluble paper are non-toxic and biodegradable.

Water soluble paper

This combined with a water soluble resin like Polyox (I should be getting a sample soon) could make for an interesting composite.

Material Samples

Alternative Fibers, Binders & Foams

1. Basalt fibers
⁃ Basfiber
⁃ http://www.basfiber.com
⁃ Tensile Strength - ~3,000
⁃ Max Temp - 560˚C
⁃ Russia
⁃ Volcanic rock found all over the world.
2. Eco-comp UV-L
⁃ Sustainable Composites Ltd
⁃ http://www.suscomp.com/resins.htm
⁃ 96% Vegetable oil, no VOCs
⁃ Produced in the UK
3. AIREX T92 foam
⁃ Airex AG, Switzerland, division of Schweiter Technologies, Switzerland.
⁃ Thermoformable, High Temperature resistance, Excellent fatigue strength
⁃ Advanced PET based foam
4. Ecopoxy Systems
⁃ Max load (lab tests) 838 lbs
⁃ High Flexibility and Tensile Strength
⁃ “EcoPoxy® forms strands of cross-linked chains of molecules that intertwine to produce unprecedented strength.
5. Oomoo 25 Silicone
⁃ Elongation at Break: 250%
⁃ Tear Strength: 40pli
⁃ Easy to use silicone rubber

What is a composite?

A composite is any material which is comprised of two or more materials. Most commonly, there's an binder or glue & a filler or fiber.

4-ply composite material created by Albeflex

Woolen felt and silicone

95% car tires and plastic containers

Fiberglass skylight pyramids

Recycled plastic lawn furniture

Carbon fiber coffee table

Concrete tents

Commercial furniture made using a range of green materials such as waste agricultural fiber, bammoo and recycled plastics, metals, and paper

Fiber glass

Aluminum composite chair