Moon mat – “Like walking on the moon!”
Goal: Create a repeatable mold
Idea: Flexible tile for use in an array for a floor mat
Initial unit tile design
Each opposing side matches both edge and slope of surface to allow for infinite two dimensional array. The filigree elements allow individual units to fasten to each other.
3D model of tile array
CNC mill in action:
1/4″ Ball nose end mill
Spindle speed: 9,000 rpm
Feed speed: 6 in/sec
Plunge speed: 6 in/sec
Stepover: 0.25 in – 50%
Final milled negative mold
Mold with hand soap release agent.
Oomoo 25 is mixed at a 1:1 ratio
Plaster mold pre-pour
Plaster mold assembled
Plaster mold broken open
Plaster top piece
Plaster bottom piece
Final tile pulls
Conclusions: The surface design was quite tolerant of mold imperfections; the other elements of the tile design were not as forgiving. The final tile do not allow for as secure of a connection as desired. Solutions to this problem would be to either thicken the filigree joint or cast the tile as a rigid base and flexible top. Additional design fidelity could be achieved by by down bit size several times rather than using only a single bit.