10. Textile Scaffold

Weekly Report: Technical Textiles

This week, we explored technical textiles and their applications across diverse fields like agrotech, construction, apparel, geotech, and sports. Our focus was on designing custom processes that involved composites, polymerization, solidification, fabric formwork, crystallization, and biocomposites.💡🎨

Assignment Objectives

Our task was to experiment with two textile scaffold techniques from the options below:

• Fabric formwork with casting🏗️
• Crystallization❄️
• Wood-textile composites🌳🧵
• Resin & bio-resin-textile composites 🌿🔗
• Leather molding 🪶

For my project, I chose:

1. Leather molding using CNC tools
2. Crystallization for creating textured, shimmering surfaces

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Research

Now, let’s explore some inspiring examples from designers pushing the boundaries of technical textiles and innovative material design! 🌟👗

Process and workflow

Tool	Description
CNC Machine	A computer-controlled machine used to cut and shape materials, such as wood or metal, based on digital models.
Fusion 360	A 3D CAD, CAM, and CAE tool used for modeling and designing parts for CNC machining.
Blender	A 3D modeling and animation software used for designing and modifying models, including CNC-related projects.
3ds Max	A 3D modeling software used for creating complex designs and patterns, ideal for CNC machining.
CNC Router Bit	Specialized cutting tools used in the CNC machine to shape and carve materials.

Leather Molding with the Help of CNC 📜

Creating custom molds for leather shaping using CNC is a fascinating and hands-on process! Here’s how I did it step by step, combining 3ds Max and Blender to make the perfect mold. Let’s get started! 🚀

Step 1: Modeling the Pattern in 3ds Max 🖥️

1. Create a Plane: Open 3ds Max and create a plane. This will be the base of your design.
2. Add Segments: Add segments to the plane (increase the width and length segments). Segments allow you to play with the shape and add details later.
3. Apply Tessellation Modifier:
   • Go to the modifier list and choose Tessellation.
   • What’s tessellation? 🤔 Tessellation divides polygons into smaller triangles or quads, making your model more detailed, like giving your design more "resolution" for patterns.
4. Adjust the Pattern: Using Edit Mesh, move vertices up and down on the Z-axis to create a 3D pattern. It's like sculpting but digitally!

Step 2: Smooth it in Blender 🌀

1. Import the Model into Blender: Export your 3ds Max model as an OBJ or FBX file, then import it into Blender.
2. Apply Subdivision Surface:
   • Add a Subdivision Surface modifier to make the model smooth and clean.
   • Adjust the levels until the pattern looks refined.

   📝 Tip: Subdivision Surface helps make edges softer and gives your mold a professional look.

Step 3: Create the Mold ⚙️

1. Duplicate the Model: In Blender, copy and paste the model to create two identical pieces.
2. Extrude the Shapes:
   • Extrude one copy upward (for the top mold).
   • Extrude the other downward (for the bottom mold).

   This creates the positive and negative spaces for your mold. Super simple, right? 😄

Why This Method Works Well 🛠️

This process is straightforward, fast, and perfect for making leather molds. Once the mold is CNC-machined, you can use it to shape leather into intricate designs!

💡 Fun Fact: Leather molding with CNC creates sharp, clean patterns that are hard to achieve manually. It’s a game-changer for custom designs!

Textile Scaffold_4 by seeyalate

Textile Scaffold_3 by seeyalate

Preparing Files for the CNC Machine Using Fusion 360

We Opened Fusion 360

We launched Fusion 360 to start preparing my molds for CNC machining.

Upload the Files

1. Clicked on the Data Panel (located on the top-left corner).
2. Selected Upload and chose the file I exported from Blender or 3ds Max (e.g., .STL or .OBJ).
3. Once uploaded, dragged the file into the workspace.

Position the Molds

• Rotated, scaled, or moved the molds as needed.
• Used the Move/Copy tool from the toolbar to adjust the molds into the correct orientation.
• Ensured both molds were aligned properly to fit the material dimensions on the CNC machine.

Here, you can watch a video showing how we did it.

ShopBot CNC Preparation

With Mkhitar's guidance, we went to the CNC room, where he explained the necessary setups in Fusion 360 while demonstrating the process step by step. Together, we prepared the file for the ShopBot CNC machine:

Operation Type: Milling

• We selected "Milling" as the operation type and adjusted the X and Y axes to fit the ShopBot’s configuration.

Manufacture Setup

• Under the "Manufacture" workspace, we started with "Pocket Clearing" and "Contour Operations" to ensure proper roughing and finishing. First, we prepared for roughing with a "flat and mill" bit, and for finishing, we used a "ball and mill" bit.

Pocket Clearing Setup

• Navigate to "Pocket Clearing" in Fusion 360.
• Choose "Tool" from the Fusion Library.
• Apply "Filter" to select "Flat and Mill, 1/4 inch."
• In "Feed and Speed," set spindle speed to 12,000 RPM and cutting feedrate to 1350 mm/min.
• In "Geometry," choose "Machine Boundary" as "Selection" and select the sketches.
• Simulate the process to ensure accuracy.

Finishing with Ball and Mill

• Switch to the "Ball and Mill" bit, selecting "1/8 inch."
• Update the "Cutting Feedrate" to 1500 mm/min.
• In "Geometry," choose "Selection" again for boundary sketches.
• Simulate this operation to verify the finishing setup.

Final Contour Cutting

• Return to "2D Contour" for the final shape cut.
• Use a "Flat and Mill, 1/4 inch" bit.
• Change the "Cutting Direction" as needed.
• Go to "Passes" and select "Multiple Depths" for incremental cutting.
• Adjust the "Stock Side Offset" to 40 mm for clearance.

Generate Code

• Simulate the final operation to review the complete process.
• Press Ctrl+G to generate the G-code, ready for ShopBot machining.

CNC Machine Safety Briefing and Operation Guide with Mkhitar

Before we started working with the CNC machine, Mkhitar took us through an important safety briefing. He made sure we were aware of all the necessary safety protocols, including wearing protective gear such as safety glasses and hearing protection. Mkhitar also emphasized the importance of maintaining a clear workspace to avoid any accidents. We were instructed to keep hands and other body parts away from moving parts and to always stay alert while the machine was running.

Once the safety guidelines were covered, Mkhitar demonstrated how to operate the CNC machine. He explained how to load the file into the machine, set up the tools, and adjust the settings for the specific project. Mkhitar also showed us how to monitor the process closely to ensure everything ran smoothly and safely. His thorough explanation gave us the confidence to proceed with our work, ensuring both safety and efficiency throughout the CNC machining process.

Here you can see a video of Mkhitar explaining the CNC machine safety rules and how to operate it.

Special thanks to Mkhitar Evoyan for his invaluable help with Fusion 360 and the CNC machine during this challenging and overloaded week!🚀

Here you can see the roughing and finishing process in action.

CNC Troubleshooting Experience

During the CNC operation, we faced multiple unexpected challenges. The program stopped abruptly three times, requiring us to restart each time. These interruptions extended the process significantly as we worked to identify the root cause and resolve the issue.

Outcome: After careful troubleshooting and persistence, we managed to resume the work successfully and complete the operation.

Experimenting While the CNC Machine Worked

While waiting for the CNC machine to complete the operation, I decided to experiment with an already existing leather mold. To enhance the design, I wanted to add an intricate pattern to the leather for a more unique and visually interesting result.

First, I opened Adobe Illustrator to create the pattern. I carefully designed it to complement the mold's overall aesthetic. After finalizing the design, I prepared the leather for cutting.

Using a laser cutter, I set the following parameters for precise results:

• Speed: 15
• Minimum Power: 90
• Maximum Power: 92

When the leather was ready, I boiled it in hot water for 3 minutes to soften it. After boiling, I carefully placed the leather onto the mold. To ensure it held its shape, I fixed it in place with clamps, allowing it to cool and set into the desired form.

The result was great, and I really like how it turned out!

Kombucha Molding: Step-by-Step Process

Preparation of Kombucha Material

• We started by carefully taking the kombucha out of its container.
• Rinsed it gently with clean water to remove any residue and ensure it was ready for molding.

Placing Kombucha in the Mold

• Positioned the kombucha sheet into the mold, making sure it fit snugly to the mold's contours.
• Adjusted and smoothed it out to avoid wrinkles or folds that could affect the final shape.

Securing with Clamps

• Used clamps to firmly hold the kombucha sheet in place.
• This ensured the material would dry in the desired form without shifting or losing shape.

Drying Process

• Placed the mold with the kombucha in a well-ventilated area to dry.
• Allowed it to dry completely, which helps the kombucha harden into the mold's shape.

This process created a unique, organic form that showcased the kombucha's natural properties.

🌿 Below, you can see the outcome of the kombucha molding process. While it didn’t turn out as perfect as we had hoped, it still showcases an interesting texture and unique form. 🌟

🧪 Crystallization Process: Step-by-Step

Preparing the Salt Solution 🌊

• Fatima and I started by boiling a pot of water. 🔥
• Once the water was boiling, we gradually added salt, stirring continuously. 🥄
• We continued adding salt until we noticed undissolved grains settling at the bottom of the pot. This meant the solution was fully saturated. ✨
• To make it more vibrant, we added a small amount of blue powder color to the solution, giving it a beautiful hue.💙

Preparing the Objects for Crystallization 🎨

• We chose a variety of materials for the experiment:
• 🍎 Apple
• 🪡 Fabric
• 👜 Leather
• Carefully tied each item with string, ensuring it could hang securely in the solution. The string would support crystal growth. 🧵

Setting Up the Crystallization Process 🏗️

• Placed the tied items into a bowl filled with the hot salt solution.
• Ensured each object was fully submerged but not touching the bottom or sides of the bowl, allowing room for crystals to grow evenly. 🧊
• Positioned the bowl in a stable spot where it wouldn’t be disturbed during the process. 🚫✋

Allowing Crystals to Form ⏳

• Left the setup undisturbed for several days, checking periodically as the water evaporated.
• Watched in amazement as the crystals formed, transforming the objects! 🌟

This process was both fascinating and rewarding, showcasing the beauty of natural crystallization.

Leather Molding: Final Steps

After experimenting with the CNC machine, we successfully created two beautifully crafted molds designed specifically for shaping leather. With the molds ready, the next step was to transform flat leather pieces into stunning, textured forms that fit the molds perfectly. Here's how the process unfolded:

Preparing the Leather

• I selected a leather piece that would work well with the molds.
• To make the leather more pliable and easier to shape, I boiled it in hot water for approximately 3 minutes. This softened the leather, making it more responsive to the contours of the mold.

Shaping the Leather on the Mold

• After boiling, I carefully placed the softened leather onto the mold, ensuring it conformed to the intricate design details.
• Using clamps, I firmly secured the leather in place. This step was essential to hold the leather tightly against the mold while it dried and set.

Allowing the Leather to Dry

• Once fixed in place, I left the leather to dry naturally, allowing it to take on the shape of the mold permanently. The drying process helped retain the texture and details imparted by the mold.

👇 Here is the result of the leather molding process. The outcome is truly exciting and beautifully showcases the intricate details of the molds we created! ✨

• Leather mold bottom
• Leather mold top