2B – Mold making

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.


4.196 Special Problems in Architectural Design Complete Fabrications Nick Gelpi Mon-Fri, Jan 5-7, 10-11, 13-14, 18, 20-21, 24-25, 27-28, 01-04:00pm, 3-402/7-432studio, 1st mtg Wed 1/5 Pre-register on WebSIS and attend first class. No listeners Prereq: Permission of instructor ; Yr-1 MArch students who have completed 4.123 only Level: H 9 units Standard A - F Grading Can be repeated for credit Lab Fee: 150 A comprehensive introduction to methods of “making” explored through a wide range of brief but focused exercises. Skills = developing complex geometries from flat components; fine-tuning press fit construction, molding and casting, and making repeatable molds for customization. A two-part workshop, the first half will contextualize contemporary tools and techniques within the trajectories of historical case studies of building, combined with hands on familiarization of tools. The second half will implement the tools of our workshop in the context of Design. Working on group design build process for three MIT 150 FAST installations, students will test and influencing designs through the instrumentality of production. These hands-on design build projects are intended to produce reciprocity between skills and design, making more complete the problems of fabrication. Subject limited to year-one MArch students who have completed core-1 studio. Contact: Nick Gelpi, 9-224, 253-9415, -


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