10. Textile Scaffold¶

Research¶

This week focused on creating structures using textiles and biomaterials, which has been one of my favorite parts of the course—full of building, and hands-on experimentation.

I had the freedom to explore several techniques, including:

Composite making (combining two or more materials)
Wood molding
Fabric frameworks
Crystallization
Wood and textile integration
Digital and biological fabrication

To support some of these experiments, CNC milling was especially useful for creating precise molds for casting.

Weekly Assignment¶

References & Inspiration¶

Eileen Schreyers Paper plisagge was well thought of and crafted.

Fatemeh Mollaie on fruit leather making.

Process and workflow¶

My focus is on using natural materials to create molds and exploring composite making using wood, fabric and sisal. I want to experiment with how these materials can be shaped, combined, and reinforced to form functional and sustainable structures. This approach aligns with the theme of working with biomaterials while emphasizing locally available resources.

First I had to learn how to operate a CNC machine.

## CNC MILLING

I had the prividege to learn ad operate a CNC machine this week with Kimani guiding me thtoughout the process.

Computer Numeric Control uses a computer-controlled cutting process where a rotating tool removes material from a workpiece. It is used on metals, plastics, wood, composites, etc.

For it it to function, the program or the design must be generated as a G-code, the workpiece clammped on the machine bed and cutting done with high precision.

Safety protocol for CNC milling¶

A. Personal safety (PPE & clothing)

Wear: Safety goggles or face shield (chips and coolant can fly out).
Hearing protection (machines can be loud).
Safety shoes.

Avoid:

Loose clothing, jewelry, watches.
Long hair untied (always tie it back).
Gloves near rotating tools (risk of entanglement).

B. Before you start (pre-operation checks)

Training & authorization: Only trained, authorized users should operate the CNC mill.
Machine inspection: Check guards and doors: interlocks should work; never bypass them.
Verify emergency stop (E-stop) works.
Inspect tools for cracks/wear; check tool is properly tightened.
Workpiece & fixturi: Clamp the part securely (vise, clamps, fixture plate, etc.).
Make sure nothing protrudes into the toolpath unintentionally.
Program verification: Use simulation or dry-run/air cut (no tool near workpiece) at low feed to check:
Correct coordinates, zero point, and tool offsets.
No collisions with fixtures, clamps, or the table.

C. During operation

Keep guards/doors closed while the machine is running.
Hands off: never reach into the machine while it’s in motion.
Stand clear of the front of the door when cutting starts (just in case of flying chips).

Watch for:

Unusual noise/vibration.
Excessive smoke, burning smell, or coolant leaks.
Use the feed hold or E-stop if anything looks wrong.

D. After machining / maintenance

Wait until the spindle fully stops before opening the door.
Clean chips with brush/chip hook; don’t blow chips into your face or other people.
Turn off the machine
Advantages of CNC milling

Compared to manual milling or other processes, CNC milling offers:

High precision and repeatability
Tight tolerances and consistent parts across large batches.
Once programmed and set up, machines can run with minimal human intervention, increase throughput, and even run lights-out in some shops.
Better process control
Stable feeds/speeds, controlled toolpaths → improved surface finish and tool life.
Integration with CAD/CAM
Design in CAD, generate toolpaths in CAM → faster design-to-part workflow and easy edits.
Reduced human error
Fewer manual operations (like hand-cranking coordinates), so less risk of operator positioning mistakes.
Scalability: Easy to go from prototype to small batch to larger production by re-using the same program and fixturing concept.

CNC Operation¶

My team were so handy during CNC operation. I ensured I had all the safety gears in place before operating the machine. First, I designed a shape using Vcarve software that I was going to cut.

Material setup- I used 18mm plywood

2D profile toolpath

Preview toolpath

Left some distace from the edges of the material to cut

Preview of visible tool path

Saving my file as a G-code

Transfer the G-code to Velocity CNC

Learned how to power CNC on

Linking my computer to the CNC machine

Changed all the coordinates to read zero and start cutting.

Biomaterial Composite¶

Been always facinated how plywood is made. Plywood is a composite material made by gluing together thin layers of wood veneer with each layer’s grain direction rotated 90 degrees from the previous one.

This cross-lamination makes plywood:

Strong
Stable
Resistant to warping and cracking
Lightweight compared to solid wood

I used the already prepared mold designed by Kimani.

Materials¶

- Soft wood
- Sisal fibre
- Wood glue
- Fabric

I had to source out sisal material from a sisal processing company. I was priviledged to lear how sisal is produced.

Sisal Plant

Processing from the farm

Wet sisal

Brushing off of some dried residues to make it more clear and then you'll have a clean sisal fibre.

I used some softwood, sisal fibre and wood glue and clamped them in between the mold.

wood+glue

The wood was 1.2 mm thichness and upon applying the woodglue and joining two more wood of the same thickness the composite had a 2.9mm thickness

Wood+Glue+Sisal fibre

The thickness was 3.0 for wood and upon putting sisal fibre the thickness was 5.2 mm.

Wood+glue+fabric

Tools¶

- CNC machine
- Clamps
- Vice