Brief
I have been given the task of designing and creating a cover plate made out of ceramic to fit on top of the myEdition tap from Axor. 3D printing and plaster will be used when making the mould for the ceramic and the design needs to be manufacturable.
Research
Ideation
Concept directions
Mock-ups
Revisions
Render(Studio)
Render(in context)
When designing the cover plate, I thought of luxury and elegance. A peacock perfectly represents that and is very symbolic in many cultures. I created the cover plate to have curves to showcase the capabilities of a 3d printer and make it easier to remove from a mould. The spaces between the abstract feathers are sufficient so that the mould walls won't be too thin.
Revision 2
I have decreased the height of the feathers and have increased the tapers so there are no edges to showcase 3d printing better. I have also added feather texture to increase interest in the design and utilize that you can have fine details with 3d printing.
Revision 3
I have removed feathers and added curved lines to showcase 3D printing lines and have increased the space between feathers to make it easier for the plate to come out of the mould. I have also increased the draft tapers.
Manufacture
Mould Making
3D printing was used to make a master that was then spray with cook and spray to prevent the plaster from sticking to it. It was then stuck done to a ABS mould box.
Plaster of Paris was mixed and poured into the mould box with the master stuck to it. It was the shaken to take the bubbles out.
Plaster was let to set over a few days so that the master could be removed later.
Slip Casting
The master was then removed from the mould using scalpels and chizels.
Unfortunely, my mould had chiped in many places. I did however still slip cast it as I had made multiple moulds that didn’t work.
Slip was poured into the mould and let to set for a few minutes. I was then able to remove it from the mould and let to fully set.
Press forming (CNC and 3D printed mould)
Since my plaster mould failed, I had to try making one using a CNC, but the details were too small as i designed the plate for the process of 3D printing. This lead me to 3D print my mould, but with a new altered design to make sure i don’t get chips and show off 3D printing lines more. I proceded to knead some clay and roll it out. I then pushed in into the mould and let it dry out in the sun.
Demoulding and Firing
The plates were removed from the mould. The first one cracked as i left it out in the sun for too long as seen in the first picture, but removed the ones after it sooner and that fixed the problem. Cover plates are now out the mould and ready to be fired. They are placed into the kiln and will be bisque fired. 3 plates were made, 1 left as it is after firing, 1 painted white and 1 painted a greenish blue.
Final Outcomes
Axor is a brand of luxury and simplicity. I have designed my cover plate around this philosophy. I looked to nature for inspiration and found the peacock to be very elegant and it carries many symbolisms of wealth and finesse. I therefore designed my cover plate to be an abstract peacock conforming to the idea of minimalism and elegance.
Reflection
This was my first time working with ceramics and although it is a patient process, I found it quite enjoyable. Unfortunately, or dare I say, fortunately, I had problems with my original process, so I got to experience all the processes. I learned how to pour plaster. CNC, work with clay and use my 3D printing knowledge. I also learnt how wet clay should be when press forming. What I would do differently is pay close attention to draft tapers. I struggled with making the plaster mould ad will design differently when doing it again. My favourite part was using my hands and being busy.
