AP projects 2015
Posts by Jorinde Smits
It is almost a week ago that the project ended with the science fair, a recap is posted on this. So we had some time to reflect on the course of the project.
We learned a lot during this project: like the various ways of scanning and software used to extract the necessary data. The most difficult part was to convert the acquired 2d images from the scanner to an editable 3d model. On the other hand, while converting, it was important to keep the planning in mind. We could have easily spent too much time doing this, which could have cost us valuable time meant for physical replicating. We then divided the tasks, two of us converted the scans and the other two researched possible printing techniques at TU Delft and by businesses around Delft. The downside of this was that not everyone got an insight into the converting process. Though in the end, the extensive blog posts and tutorials, the work done cleared it up for everyone.
After finishing converting we could adjust or add elements to the chosen cup (Harry) to make reproductions. We had to keep in mind that the old footprint had to be preserved. You quickly tend to replicate the cup and give its original look. Yet to make it attractive and interesting for the modern user you have to be original. Therefore, we all chose individual design approaches. That made it very beneficial for our CAD skills. Yet in the end, we all had designs with similarities, due to information exchange during group work sessions.
On the one hand, our assignment was to give back the purpose to historical objects. On the other, there are more options than to just make it into a mass consumer product. It was nice that Maaike left us free to choose our own goals. This way we managed to create four cups with completely different purposes, which was not without its educational benefits. Though, for next year it would be nice to have the supervisor’s expertise as the axis of the project. In Maaike’s case, it would be great to get guidance in porcelain production or augmented reality. It would be nice to see how our work could positively influence her practice or actually give some input to the field.
Summarized, it was an educative project with a possibility to try out various unknown technologies for us. Yet it did not always go smooth, due to some miscommunication. Yet all of it was so minor that it did not give any repercussions neither to the timing, nor to the final products.
As told in the planning, each of us would come up with a multiple reproduction methods for Harry. We pitched these ideas to each other and discussed which would suit the purpose of this project best. Afterwards everybody choose their favorite and best method, making sure we had a diversity of production techniques.
Sander Plaster Print
The goal of this technique is to recreate Harry as well as possible. Therefore, the existing cup will be plaster printed in several pieces. Af varnishing the inner and outer surface, these pieces will be glued together in order recreate the cracks. The holes shall be filled with separately (Ultimaker) 3D-printed parts.
Irene Paper printing
Using the technique of 3D printing paper it is possible to make a relatively inexpensive product using a 3D printer. We don’t expect this technique to be waterproof. By experimenting with lacquer or varnish we can find out the possibilities to make the cups usable for daily usage. To print the rough version of Harry it will cost €34,- euros.
Kotryna 3d printing/plastic injection molding
With this technique we could achieve a very sophisticated look for a high end product. With this design we would bring out the beauty of 3D printing by making an expressive carcass which will either support the cavities in the structure or the whole structure. This also accentuates the historical marks on the object, which is necessary because the original form is then recreated in transparent material. The latter can either be achieved by plastic injection molding (which is beneficial if this is produced in larger numbers) or by using a Objet500 Connex printer (very convenient, because the whole object can be printed out in one go). Moreover, this design would be very interesting if steel 3D printing could be achieved in very small diameters, since then the translucent material could be glass.
Jorinde Vacuum Forming
The main reason for choosing this technique is because 3d printing is too expensive for a consumer product, so the product is still not used for its purpose. The most used cup has got to be the plastic disposable cup. This cup is made with the technique thermoforming, but this is not achievable in the short amount of the we have. Therefore the simplified technique vacuum forming will be used. With vacuum forming s sheet of plastic is heated and forced against the mold by the suction of air. It is important that form is mold-releasing.
With this technique it isn’t possible to use different materials or make holes. To preserve the historic character of the cup the difference between the shards will be made visible with a difference in height. CNC milling at PMB cost 10 euros.
|Basic (existing) shape||Cracks||Holes||Speciality|
|Sander||Plaster, several separately printed parts||Through glueing the parts together||Seperately 3D-Printed||Trying to recreate Harry as well as possible|
|Irene||Paper||Different colour||Low budget|
|Jorinde||Plastic, vacuum formed as one part||height difference
between the shards
|Holes have to be filled, visable with height difference||Making an old thrown away cup into a useable and disposable product|
|Kotryna||Plastic, (partially) 3D printed (and plastic molding)||Surface texture, carcass deformations||Carcass or carcass deformations (depends on the final design)||Showcase of 3D printing possibilities and accentuating historical footprint in newly added details|
While still being occupied with the processing of the CT-scans, the first impression was that it wasn’t as easy and accurate as we expected it to be. Maaike had reserved the Artec Spider for Friday for another project. We wanted to see if this scanning technique gave a better or different result then the CT-scanners. We were lucky that this was possible.
The Artec Spider is a scanner for small objects that captures really complex details and color. It has an accuracy up to 0.05 mm.
We scanned three objects:
- The comb, because this object is the only object that was scanned by the macro and micro scanner. Scanning this object with the Artec Spider will show the difference between these three scanners.
- Hermione, to see if the accuracy of details is better with the Artec Spider.
- Harry, to see if with this technique the break lines and repaired break lines will be visible
In the files from the CT-scanner the repaired break lines weren’t visible and the break lines were given an arched shape.
The objects and the scanner had to be moved/operated by hand, since the objects were so small. For the comb this wasn’t a problem because we put it in a paper cup and turned that around. The scanner has problems with really small or big gaps. The small gaps in the comb were too small, in the model there was a relief instead of gaps.
The problem with Hermione was the big gap on one side. Because of the gap the model had a lot of failures. We tried multiple ways of scanning. Eventually we scanned only the handle, by making multiple scans from different angles and combining them together.
Because of the problems we had with Hermione we decided to fill Harry with a napkin, so that no problems would arise from the difference in distance. This went ok, only afterwards the napkin had to be deleted.
The results of processed 3D images will be posted later.
We had to make some choices since there were a lot of bowls, plates, hair brushes and other ceramics. To distinguish them we gave them names. We joked about ‘Harry Pottery’ and decided to choose the names from Harry Potter characters. We based our choices at differences of advantages and interesting characteristics. Since we didn’t know how much time it would take to digitalise the cups and plates, we numbered them in order of importance.
We took in account the different types of advantages.
To make the cups useful again, we need to fix the holes.
Some cups like Harmione and Hagrid have some nice details. Since the CT scanner is not that accurate we have to find other solutions for bringing those details back.
- Fixing techniques
There are different ways used for fixing the objects. How can we translate those methods in our new design?
We decided to exclude the hair brushes in our process, because it has nothing to do with tableware.
Here the advantage is to replace the three separate shards. Diameter of +/- 18 centimeters.
Small plate. Missing a piece and two repaired cracks. Diameter of +/- 15 centimeters.
Kind of fruit bowl with lid. It has nails and glue as fixing methods. The cracks are really fragile, but as good as complete. Diameter of +/- 25 centimeters.
We liked this small cup because of its small hole. Diameter of 5 centimeters.
This one is familiar to Hagrid, but much smaller. The one defect is the bottom which is fixed. The cup is complete. Diameter +/- 15 centimeters.