Pim van Baarsen
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Unfortunately that was the only weaving project.
For the materials you can use all kind of stuff. The PP/PS was quite stiff and especially the start was hard. The thinner your wire, the easier the weaving.
Would say that PET also could work well.
I would take thinner iron wire the next time. Like the baskets from the movie above. Nice details.
Well, I had not so much trouble with sticky plastic.
You could check the “baking” time. Too long in the oven can make the plastic too sticky. Just a possibility.
Thoroughly cleaning the mold after using can make a huge difference.
And like procastino mentioned, oven paper could be a great help.
Never tried it but can imagine that it useful.
I’m so sorry for my slow response…
Hope I can still help you out by replying :-/
Your mold looks great. The mold I made works the same way and had good experience with it. I only had some difficulties with the metal sheet that started bending a bit after time, which had effect on the plastic sheet that came out. It was not super straight unfortunately. Especially difficult when you want to further work with it in lasercutter for example.
* I didn’t use anything to make unmolding easier. Didn’t had big issues with that to be honest. Sometimes the plastic was melted around the screw-thread or in between the flatbars. But most of the time I was able to remove it after some cooling down.
Sometimes there were some plastic flakes (probably another kind of plastic) that sticked to the mold. Thoroughly cleaning the mold after using with a spatula worked best for me. My experience is that every singel piece of plastic or plastic assessment remaining in the mold, could make it sticky.
Never thought about oven paper. Can imagine it it works fantastic!
* I did a lot of tests with changing the amount of plastic, the temperature and time. On the end I had quite a good idea about the right proportions and settings.
* Holes in the lid could work!
My mold just pushed the plastic out on the sides. But can image that a few holes works better 🙂
Love the result!
Can you tell something about the temperature and time in the oven?
I did a lot of experiments with PP and PS and found these are really specific settings. Would love to do some ABS experiments and would be awesome to have q kickstart with that kind of information 😉
I had the same. Sometimes it was really impossible to remove the plastic from the mold… It literally cost me some molds 🙁
Didn’t find the reason for that. Think it has to do with the time in the oven and temperature. It also depends on which materials. It seems that some are more sticky than others.
There are sprays on the market to spray your mold and prevent it from sticking to the plastic. It sounds really chemical to me and tried it one without result. But maybe I had the wrong one or didn’t use it the right way.
I don’t know how to build one.
Sounds complicated to me… There are quite some difficult parts that need te be really precise and acurate.
Maybe there’s a fablab that’s willing to help?
Hi Hexahelix, sorry for my super slow response…
I made the plastic sheet material with a tweaked kitchen oven.
Making a simple mold, and keeping it on the right temperature in the oven while pressing material is all you need 😉
I absolutely can recommend to build one yourself!
Sorry for my super slow response.
The weaving took me a couple of hours. Guess something like 3 or 4…
I used the extrusion machine of Dave. We share our workshop, that’s why 🙂
Your project sounds cool. Could be a awesome addition on local crafts.
Any progress with the starting up if it all?
The difference in material thickness makes it not connect super perfect, but actually quite like it this imperfect way!
Like a old fashioned cigar box, I used a finger joined connection and small hinges.
Like the result, though I say so myself
Some other types pressed in the mold.
There is a relationship between the amount of granulate, temperature and time in the oven.
The blackish sheet was too long in the oven which made it a kind of caramelized on the sides. If I had used more granular, the corners would be melted too.
To prevent the sheets from bending, I kept them in the mold till it was cooled down.
Pressing it on a flat surface is also a possibility.
The mold turned out to work quite good and amazingly consistent.
I tried it with several different types of Polypropylene and polystyreen.
First with the 5 mm flat-bar frame, later with a 2 mm.
The last one appeared to be too thin and got damaged pretty quick in an attempt to get the plastic sheet out of the mold.
After removing the sheet, I cleaned the mold with spatula or even sandpaper.
Scratches caused by cleaning, became more and more visible in the plastic sheet itself.
Good to keep in mind when needing really proper and clean sheets 😉
Ones I was done with the plastic wire, I wove the round-bars trough the remaining “ribs” to have a nice and firm finished edge. The first bars were quite easy to weave, ones halfway it became tough… Especially the final ones were almost impossible. Slightly thinner bars should make it much easier. Something to keep in mind for the next time 😉
The beginning was a bit hard. Despite I took the thinest plastic wire the filament extruder gave me, the wire seems too stiff for the first rounds. Later in the process thicker wire was much nicer to work with. The ticker, the better actually!
Finally finished the hat 😀
Simply saw away the crusty edges with the belt saw and sandpaper it.
You can peel of the rough edge that will remain, with your nail.
The bowl-molding technique does not always works perfectly.
Guess this one was in the oven too long…
Found a faster and easier way to press the two bowls together.
Four clamps will do the job. It saves a lot of tightening nuts and the result is nice 😉
The first sheet is not completely melted, but not bad for a first sample
After testing some different oven settings and plastic volumes, I’m pretty proud with the result!
The blades are now finished with the handle, made with the plastic extrusion machine.
Only have to sharpen them!
Made two more knifes to make a extrusion-handle for.
Now only waiting for the machine to be heated up!