COMPOSITE

My idea was to form a composite tile with doubly curved surface using burlap and resin.

1. The first step was to apply a mixture of soap+oil+water on the mold. This is to ensure that epoxy does not get glued to the cnc mold and is easier to remove the cast once it is settled.

2. Next step was to make a mixture for resin plus catalyst.

   I used silicon powder to give density to the cast since I wanted to use it as a tile

   And for hardening fast, i used Cobalt as catalyst.

I took the following proportion :

GP resin ( 1 liter ) + Silicon powder (100 gm) =  Cobalt ( 2 teaspoon)

I mixed the mixture properly and then quickly applied a layer to the cast and let it dry for 5-7 minutes.

3. Next I cut the burlap fabric to a size slightly bigger than my mold and placed it over it. Then again made the mixture of resin + silicon powder + catalyst and applied it quickly over the burlap. My design had a valley on one edge where more material got collected and I could see fumes as the catalyst reaction started hardening the cast. In 3mins or so I added another layer of resin mixture and then let it set for 10mins.

4. While it was hardening, I cut the extra fabric in line with the shape of my mold. It took about 15mins to harden about 80% to its strength. I removed the cast from the mold after that and let it dry for few hours on its own to achieve its 100% hardened state.