10. Textile Scaffold

Research

This week, I've been using Grasshopper and Rhinoceros 3D to create a bag. I've also used the scaffolding technique to prototype it, starting with a 3D model in Rhino and then cutting a two-part mold from insulation foam on a CNC. Beyond that, I've been experimenting with different materials to create crystals on fabric.

References & Inspiration

1. Unknown Author, Bag Pinterest
2. Craig Green, shoes collection
3. Christa Van Der Meer
4. Leather mould, Lemaire, SS17
5. Silia Zanchez

Tokujin Yoshioka's "Crystallize" exhibition at Tokyo MOT showcases his interest in nature's delicate structures. The exhibition features sculptures and installations that explore crystal formation and the interplay of light and space.

Tools

• Adobe Illustrator
• Rhinoceros 3D
• RhinoCAM
• Grasshopper

Process and workflow

Step #1: Conceptualization and Design

Sketch, Germarilis Ruiz

Conceptual 3D model Conceptual design #1, Germarilis Ruiz

Step#2: 3D modeling process

• Use the line tool to draw a 4-sided polygon, with the smaller top line
• Use fillet to round the corners. In my case, I used a 1" fillet for a 13"x 6 " x 5" model (length, height, width)
• To create the bag handle, mirror the original shape and rotate it
• Scaled the shape parallel to the sidelines
• Use an offset to set the handle thickness (2")
• Create a pattern in Grasshopper
• Start by extruding the handle by 1" and then extruding the bag polygon by 3"
• Boolean union (pattern + Rhinoceros geometry)

  This dimension will be duplicated when you create the two-part mold

• Duplicate the surfaces, create a rectangular base, and use the Boolean union to create the first part of the mold.
• Then, generate a rectangular volume, place the copy of the first part of the mold, and use the Boolean difference to create the second part

Conceptual design #2, Germarilis Ruiz

Step #3: Pattern design

To create the pattern, I searched for architectural facades in Grasshopper and used a pattern that resembled a textile. I followed the instructions in this tutorial (click) and then edited the pattern by changing the number slider and the graph map style in Grasshopper.

Grasshopper explorations, Germarilis Ruiz

Final pattern, Germarilis Ruiz

Grasshopper Map, Germarilis Ruiz (Zoom in to view details)

Step #4: Iteration

Conceptual design #2, Germarilis Ruiz

Final prototype, Germarilis Ruiz

Step #5: 3D Mold

3D two parts mold, Germarilis Ruiz

RhinoCAM

• Open Rhinoceros
• Open Your Document
• Right-click RhinoCAM: In the top toolbar
• Select Milling: From the dropdown menu, choose the "milling" option
• Material Settings: Define the material properties of the workpiece
• Start Point: Indicate the starting point for the machining process
• Material Dimensions: Input the exact dimensions and thickness of the material block
• Machine Tool Settings: Select the appropriate cutting tool (bit) for your operation based on the material and desired finish

Programming the Toolpaths

• Select the part of the model that requires a roughing pass (removes the bulk of the material)
• Select the areas that need a finishing pass
• Create a bounding box around the material to define the machining area
• Generate a contour curve along the bounding box
• Create a profile toolpath along the contour curve to cut the material
• The simulation will visually represent the machining process, helping you identify any potential issues

RhinoCam Settings, Germarilis Ruiz

Step #6: CNC Machining

CNC machine settings, Germarilis Ruiz

• Measure material
• Create a G-Code file
• Before operating the CNC, configure the cuts and finishes of your design in RhinoCAM
• Secure the material to the CNC bed using a screws
• Verify and change the bit if necessary. Use two wrenches to secure and loosen the bit
• Finally, configure the Z-axis and start
• Remove the material
• Once the design is cut, remove the material
• Ensure there's adequate clearance to press the leather into the mold. If the mold is too tight, gently sand it to create more space

Insullation Foam - Two parts mold, Germarilis Ruiz

Josep Mati CNC & RhinoCAM tutorial - CNC workshop

Step #7: Leather Preparation

• Boil the leather for 10 minutes to soften it
• Remove from the water
• Stretch the leather
• Carefully place it into the mold (part one)
• Secure the second part of the mold over the leather
• Apply clamps to hold the mold in place and allow the leather to dry for 24 hours

CNC milling process:

Leather molding Process

Leather molding, Germarilis Ruiz

Crystallization

Tools & materials

• Borax Powder
• Copper Sulfate
• Alum powder
• Plastic & Chrystal containers
• Spatulas
• Stove
• Gloves
• Water
• Fabrics
• Pigments (optional)

Process:

Step-by-Step Instructions:

• Sterilizing Containers and Tools
• Start by boiling 2.5 liters of water

• Place the cloth inside the container, making sure it’s as flat as possible.

  Tip: If your cloth has small holes or perforations, it can actually help the crystals grow faster.

• Slowly pour the alum powder into the hot water

• Mix the Dye
• Pour the alum and dye solution into the container with the cloth
• Cover the entire setup with another piece of cloth
• Place the container in a dark area and let it sit undisturbed for three days

Tutorials & References:

• Crystalverse

Ingredients & Recipes

- Alum 400 gr
- Water 2.5 L 
- Set time: 3 Days
- Natural Dye 1 Spoon

Crystals Recipes

Borax Powder

- Borax powder 150 gr
- Water 400 ml
- Set time: 24 hr

Copper Sulfate

- Copper Sulfate 200 gr
- Water 200 ml
- Set time: 24 hr

Alum Crystals

- Alum powder 60 gr
- Water 500 ml
- Set time: 24 hr

Results

Alum Crystals, Germarilis Ruiz

Tutorials & References:

• Crystalverse
• Petra Garajova Crystalization Tutorial

Other Prototypes

I thought it was a great idea to use modeling clay to replicate wooden furniture details and turn them into unique buttons and brooch covers.

It was an amazing week of learning and experimenting. I'm super excited about the new techniques I've picked up and plan to use them in my next project.

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Fabrication files

• File: Grasshopper
• File: Mold

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