Fabrication Process¶
After spending months researching materials, mechanisms, and creating 3d protoypes this is the final process
The fabrication process consisted of two separate lines.
The Cocoon Theatrical Piece¶
To Summerize the fabrication process of the Cocoon piece here are the main highlights:
- Getting all designs ready for printing using the appropriate slicing tools for each 3d printer
- 3d printing the shoulder pieces using PLA filement on an ultimaker 5 3d printing machine.
Settings were chosen to balance speed, strength and fine finish.
- 3d Printing the Cocoon Pieces using PLA pellets and some random autumn colors palettes
- Sanding the Cocoon Pieces and smoothing the connection area to the shoulder piece
- Spray paint one face of each Cocoon piece
- Sanding the other face of the Cocoon pieces to get rid of any spray paint that got stuck on the wrong side.
- Cast Resin and gold leaves on the sides of the cocoon to prevent any extra movement. In orderto do that I had to do it in two phases casting eachside of the cocoon shell pieces at a time. I fixed the pieces in place a base of baking baker as to not stick to the tabletop and toped the pieces with wood pieces that I found in the lab on top.
I used wood clamps to flatten them up. While fixing them I had to make sure the lines of eachpieces is taking it's maximum stretch as to widen the piece and get a proper space underneath when bended.
The resin itself was using epoxy
- Sanding the Extra Resin off the connection areas.
- Drilling 2 holes on the 2 connection areas of each cocoon piece to connect them together using fishing wires
True Skin CatSuit¶
To Summerize the fabrication process of the True SKinge here are the main highlights:
- After finishing the catsuit pattern and testing it on the performer.
You can download the dwg file with the fabric layout design for a catsuite through this Link
- Dye the fabric using tea leaves
-
Cut the Final Catsuit pattern and sew the final piece and test on the performer
-
3d print the final molds using PLA
- Casting Silicone Eco flex 30 mixed with Mica powder colours, Bentonite Clay, Gold leaves in the 3d molds to create different shapes, Nude colours, and textures. Around 25 Casts.
- Printing the degrading Catsuit pattern ( based on Chakra energy concept ) on a paper roll
You can download the dwg file with the silicone layout pattern design throu this Link
- Laser cutting acrylic sheet into the layout of the catsuit to act as a separator between the back and front of the catsuit so I can fix the silicone pieces on the catsuit without them Sticking to the other side.
-
Inserting the acrylic layout in the Catsuit with the cut paper layout ( the degrading effect ) beneath the see-through acrylic sheet.
-
Using the same material ( silicone Eco Flex 30 ) to fix the pieces into the mesh fabric of the catsuit and repeating the process on the other side.
- Flipping the Catsuit inside out and reapplying Eco flex 30 on all pieces to make sure it stays in place.
Here is a 2 min video that explains a bit of the concept, and shows some parts of the fabrication process along with some parts of the final product.
The Video link will be added as soon as I get approval for the logos from my Sponsor Company.
Here is the BOQ for the final outcome without taking into consideration testing,fails, extra pieces or shipping.
| Qty | Description | Price / Unit | Total Price | Source | Notes |
|---|---|---|---|---|---|
| 400 g | PLA Pallets | 0.40 $ | 160.00 $ | ||
| 300 g | Epoxy - Resin | 0.05 $ | 15.00 $ | ||
| 10 pieces | Gold Metalic foil leaves | 0.50 $ | 5.00 $ | ||
| 10 colours each 5 g | Mica Powder Colours | 03.00 $ | 15.00 $ | ||
| 300 g | PLA filament roll | 0.030 $ | 105.00 $ | https://www.amazon.com/HATCHBOX-3D-Filament-Dimensional-Accuracy/dp/B00J0GMMP6?th=1 | |
| 1 Unit | Bio Silicone EcoFlex 00-30 (each 1 bottle) | 41.49 $ | 41.49 $ | https://www.amazon.com/Ecoflex-00-30-Super-Platinum-Silicone/dp/B00CA5VY3U/ref=sr_1_9?crid=2TEAONAAOCR9M&keywords=silicone+30&qid=1651964953&sprefix=silicone+30%2Caps%2C225&sr=8-9 | |
| 2 m2 | lycra mesh fabric | 07.00 $ | 14.00 $ | ||
| 10 g | bentonite clay | 0.10 $ | 1.00 $ | ||
| TOTAL | 385.00 $ |