PLASTER WORKSHOP 3

PLASTER

Plaster and clay - 21st November 2017

The session was a one to one session with the technician Ms Claire on discussing about the formwork I have created and how it can be used to make a plaster model. 

The picture below shows the final mould that I have created using wood. According to the previous lesson, before the session began I applied petroleum jelly as a release agent on the surfaces of the formwork. 

Figure 1. Wooden Formwork 

However, after assessing the mould, the technician explained that the formwork I made may not be so successful as a mould as there are too many undercuts and this may obstruct the plaster to come off once it is casted. She also explained different ways I can use this formwork to create a clay mould on which I can cast a plaster model. This plaster model will then be used as the mould to cast the final piece. 

A thick piece of clay was rolled onto the wooden formwork so that the clay sits into the voids of the formwork. But since the wood has been coated with a release agent, it was difficult to get the best results with the clay. 

Figure 2. Wet clay is rolled before taking 

The picture below shows the clay mould after it has been peeled off from the formwork. 

Ms Claire advised that I can try to shape the clay using the shaping tools to create a form that I wanted. This was one of the advantages of using clay as a mould, as it can be shaped into any form. 

Since the clay that was used was quite wet, the clay mould had to be kept to dry before any shaping. 

Conclusion

Though I was not successful in using the laser cut formwork for casting a plaster model, the session introduced me to different ways I can use the formwork to make a clay mould which can then be used for a plaster cast. Next time, when I am working on a plaster model, I will be careful with the type of material I am using to make the formwork. In addition, its important to identify whether the use of a cast is the most appropriate method to use for any specific project that I am working on. Because otherwise, depending on the kind of project, I may not be able to get the most effective results. For example, if my model has a lot of undercuts, a laser cut wooden formwork may not be the most ideal mould to use to cast a plaster model. 

PLASTER WORKSHOP 2

CASTING A PLASTER MODEL

This post demonstrates a plaster model that was casted for a project of Critical Urbansim Unit 2. 

1- A release agent is applied on the surfaces of the wooden formwork to ease the removal of the plaster model once casted. 

Figure 1. Laser cut formwork

2- Formwork is fixed on the boards using clay. The clay helps to seal the formwork to make sure there are no leaks when plaster mix is poured in. 

Figure 2. Clay used to seal the formwork

Figure 3. Formwork sealed on the base using clay 

3- Plaster mix is made using 1pt of water for 1.5pounds of plaster powder. The ingredients are measured accurately to avoid any mistakes. 

Figure 4. Water poured into bowl for mixing plaster

Figure 5. Plaster powder transferred into water

Figure 6. Mixing of plaster powder with water

Figure 7. Formwork ready for plaster

Figure 8. Plaster Mix

4- Plaster is carefully mixed to avoid any lumps from forming. Once the mixture becomes slightly thick, it is poured into the formwork.

Figure 9. Plaster poured inside the sealed formwork

Figure10. Plaster set for casting

Figure 11. Plaster set for casting

 Below shows pictures of the plaster casts removed from the formwork. 

Figure 12. Final outcome

Figure 13. Final outcome

Figure 14. Final outcome

Conclusion

This was my very first attempt in casting a plaster model, and the simple formwork structures made it a good learning exercise. Some of the points to look out for in the future sessions include:

• Stick with the ratio stated to avoid any mistakes.
• Make sure the plaster is mixed well, without any lumps.
• Dont pour in plaster too quick. Make sure the mix has started to thicken. 

PREPARING FILES SESSION 2

Laser cutting session 2 (Formwork model)

Preparing files

For this session I have prepared the AutoCad file of the base where I have offsetted the lines that I want to etch, so that they fall in between the building blocks. In order to create additional thickness, I have drawn a frame which would add to the stacked frameworks already cut. 

The figure 1. below shows the screenshot of the files ready for the session. 

Figure 1. Screenshot of AutoCad file

DIGITAL WORKSHOP 3

Laser cutting session 1 (Formwork model)

I had my files for the formwork model prepared for the session on 13th November, as it would be a good opportunity to discuss the file with the technician, and proceed with the laser cutting. 

Materials

I showed him pictures of how i want the model to be and asked for his advice on the thickness of boards that I can use for laser cutting. The thickest boards available are 6mm, so I decided to cut 3 layers of the model to give the formwork an appropriate thickness for the plaster casting. 

Etching and Grooves

As for the etching, I asked the technician that I wanted to create a groove instead of an etch so that when plaster is poured in it would leave an etch on the surface of the cast. So the technician explained that he would give the lines a depth and thickness before sending the file to the laser cutting machine. 

Laser cutting process

Below are pictures and videos of the process. 

Figure 1. Dwg file imported onto software for lasercutting by the technician

Figure 2. 6mm thick board loaded into laser cutting machine

Figure 3. Laser cutting process

As shown on Figure 3. the three similar cuts of the street network will be stacked on top of each other to provide depth. The piece in the middle will be the base which will imprint the grooves on the plaster cast. 


Conclusion

After the cutting process was over, I tried to remove the pieces from the board. Since it was a thick board, it was quite hard to remove the pieces as in some places the laser was not successful in cutting through. However, I managed to remove the pieces for two of the framework, but for the last one I accidentally broke a part of the frame while removing the pieces. 

In addition to this the grooves on the base piece did not come out as I expected as I must have accidentally drawn the street lines aligned with the framework as seen below in Figure 4.   

Figure 4. Laser cut framework stacked on the base

I have learned that it is very important to check the files carefully before going to the workshop to achieve the most outcome during a session. 

Luckily, I had an additional session booked in case I needed to laser cut further, so I adjusted my files accordingly. 

DIGITAL WORKSHOP 2

DIGITAL PRINTING

Laser cutting - 13th November 2017

Introduction

Laser cutting is a helpful tool that can be used for various types of models. During the session we had, the technician explained the different colours that are used in preparing the files. for example: red is used for cuts, blue for etching and black infills are used for rastering. 

Mainly, the type of file required is vector file. It could be a dxf, or dwg etc. A1 size is the maximum size of a sheet that is used for laser cutting. 

Figure 1. Laser cutting machine

Figure 2. Ongoing Laser cutting process 

The picture above shows the three types of files prepared for laser cutting. The dark blue one for etching, the black infill for rastering and the red for cutting.

The pictures below shows different types of pieces and models I can make using the laser cutting process. It was quite interesting to see the different types of cuts, their sizes and etches that can be made on a model to bring out different characteristics of the model.

Figure 3. Model with different variations of cuts and etches.

Figure 4. Model made with rastering 

Figure 5. 3d art piece using laser cutting

Conclusion

The session on laser cutting introduced the class to different types of results that can be achieved on different types of materials. Similar to the session on 3D printing machines, this session is also useful in determining whether laser cutting is an appropriate method to use when working on a specific project. It also exposed me on basic things I need to know when preparing files for laser cutting, and how much time each process takes, which would be useful in time planning in future projects involving laser cutting. 

PREPARING FILES SESSION 1

Preparing files

According to our brief, we are supposed to create two physical models using the techniques we have learned in the workshops. I have completed a workshop session in both Ceramics and Digital printing and I did some research on how I can combine both techniques to create a model. ­

Concept

In one of our units, Research and Theory, there was an interesting lecture on perspective and order in architecture and demonstrated an urban space in Rome known as the Piazza del Popolo as one of the examples. The layout of the urban square and the streets emerging from it are designed in such a way that if a person is standing in the center of the square, the streets provided maximum visual access of the city ahead. The design of the square and the area around it is highly geometrical and therefore would be an interesting to create a model of this urban space. 

Figure 1. Aerial view of Piazza del Popolo taken from Google Earth.

Work process

As a first step, I traced a map of the area of Piazza del Popolo on Autocad to create a 2D file that can be used for laser cutting. Since I have not tried laser cutting before, I did some research on how to create a 2d file on autocad for lasercutting purposes. According to a youtube video reference (see reference details under bibliography), I understood that I would require a template file through which I can coordinate specific colours which defined the nature of the cuts.

My plan is to create a wood formwork of the street network of the area using laser cutting techniques. And then by using that formwork, to create a plaster site model of the area. Inorder to visualise how I want the model to be done, I made a 3d model in Autocad.

 

Figure 2. Screenshot of model on AutoCad

Figure 3. Screenshot of model on Sketchup

The model shows the streets (voids) extruded, since the formwork model I have to create will need to have empty areas for built up spaces, so that when plaster is casted, these spaces would become solid and the streets would be empty. 

Figure 4. Screenshot of Sketchup model 

Figure 5. Screenshot of Sketchup model

The pictures above show how the plaster model would come out once casted. 

AutoCad file

I have prepared a basic Autocad file that can be used for laser cutting. I have used two colours, each assigned to a specific type of cut I want. According to the workshop at BCU, red is used for solid cuts and dark blue is used for etching or to create grooves on the surface. 

Based on this I have prepared my file to be used on my super studio workshop session on 13th November 2017.

Figure 6. Screenshot of files prepared for laser cutting session

BIM WORKSHOP 2

BIM

Introduction to Revit - 6th November 2017

The session was an introductory lesson on Revit which included drawing grids on plan view, creating floors, walls and a roof. This session was very helpful as it demonstrated basic initial steps to start a project in Revit.  

Below are the notes taken on the session, and screen shots of the process.

Figure 1. Sketchbook notes

Figure 1. Reference lines drawn to form grids.

Figure 2. Dimensions added to the gridlines.

Figure 3. Floor drawn using the reference lines as a guide.

Figure 4. Height levels and dimensions added on sections

Figure 5. Walls drawn on the periphery of the floor.

Figure 6. Properties of the wall edited using Edit type tool 

Figure 7. 3d view of the work so far. 

Figure 8. Walls copied to the corresponding levels and a roof is added on the top level.

Figure 9. Using the architecture tab, stairs added into the interior of the building.

Figure 10. 3d view of the stairs

Conclusion

This lesson was a quick run through of how to start a project in Revit. Though it introduced basic elementary steps of drawing a building, the lesson went quite fast, and since I have just started to use Revit, I had trouble keeping up. So it would be very helpful to refer to Lynda tutorials and redo a similar tutorial on the basics to familiarize myself with Revit. 

DIGITAL WORKSHOP 1

DIGITAL PRINTING

Types of 3d Printing (materials) - 30th October 2017

Introduction

The superstudio session on digital printing introduced me to different machines used for 3d printing. The technician also demonstrated the advantages and disadvantages of each one of these machines, showed examples of printed models and provided a brief explanation of the type of materials used for printing. In addition, he explained that the files need to be saved as an stl. file to be used on these machines. 

The following are some of the machines available at the workshop:

1- ZPrinter 450

Figure 1. ZPrinter 450

ZPrinter 450 is a powder based printer which can be used to produce complex and refined models. One of the advantages of this machine is that it creates very fine intricate models, and models can be printed in colour. This can be used to make final models of designs. The file required for this machine is an stl file and it can be exported from sketchup, revit or solidworks. 

Advantages

• creates very fine intricate models
• models can be printed in colour
• can be used for final masterpieces

The file required for this machine is an stl file and it can be exported from sketchup, revit or solidworks. The bed size of this machine is 270sqm, so models need to be scaled down to fit to this size, or models can be broken down into sections and printed.

Disadvantages

• models can be brittle, but superglue can be coated to make it stronger.
• There is a small charge to use this machine.

1- Stratasys 3d printer

Figure 2. Stratasys 3d printer

Advantages

• Can be used to make models with moving and interacting parts. 

Figure 3. Screwdriver made from Stratasys

Disadvantages

• No coloured outcomes can be achieved

1- Ultimaker 3d printer

Figure 4. Ultimaker 3d printer

Advantages

• Can be used to make prototype models. 

Disadvantages

• Time consuming depending on the design

When using this machine it is important to be careful in prepping files. It would be important to discuss with the technician about the designs and the outcomes i would want to achieve during the process of preparing my files. This tool will be useful in testing out and experimenting prototype models and massings. 

Following are some of the models that the technician showed which was made using this machine.

Figure 5. Model made using Ultimaker

Figure 6. Model made using Ultimaker

Conclusion
This session was helpful in getting to know the type of machines and facilities available in the digital workshops. It also informed the advantages and disadvantages of the machines, which would be a useful in trying to decide on which type of 3d printing to use when working on a project. Each machine produces different type of material finishes and level of detail, which would also help me to decide a type of 3d printing to use to achieve specific results.