Materials & Matter for Curious Designers

precision embossed metal

2011-12-28T12:54:00.001Z

Traditional metal packaging, such as this tinplate (tin-plated steel) biscuit tin, is printed first and then embossed. High quality reproduction is achieved, because the registration between the offset lithographic print and the embossing is very precise (metal is stiff and so can be very accurately registered in the tool). Pressure is applied to form an indent, known as deboss, or a raised surface profile, known as emboss.

Image from Graphics and Packaging Production (The Manufacturing Guides)

graphics and packaging production (the manufacturing guides)

2011-12-28T12:52:00.001Z

Graphics and Packaging Production is the new book in the Manufacturing Guides series due to be published by Thames & Hudson January 2012. 

Thames & Hudson UK and Thames & Hudson US 

industrial craftsmanship: metal spinning

2011-11-29T09:22:00.000Z

Spinning is a sheet metal forming process used to produce rotationally symmetrical parts, like hemispheres and cones. Undercut profiles and parallel-sided parts – like this base of a Mathmos Lava Lamp made from a single piece of material – are possible with split tools (can be taken apart to be removed). 

Spinning is used to form aluminium. Anodising is used to protect and add colour to the surface of this material. See also bright anodised aluminium.

Image from The Manufacturing Guides

cheese basket

2011-09-04T13:20:00.000+01:00

The challenge of packaging and producing food has created some of the most beautifully efficient and practical design (see also chestnut leaf packaging and bright metallic packaging). This handwoven basket mould is used for cheese-making in Greece. The rigid structure maintains its shape under pressure and the open weave allows for excess moisture to drain away. This helps to produce a cheese with the correct density and texture. 

tubular weaving

2011-08-25T15:55:00.002+01:00

Industrial tubular weaving is a computer-guided process that has similarities with basket weaving. The warp and weft are interwoven to create a dimensionally stable, seamless structure. This process is used in a variety of applications, such as to make fingers for gloves, boot linings, sleeves, socks, nets, pipes and packaging.

In this case continuous lengths of polyethylene (PE) are woven into a tube, which will be filled with animal feed and sealed to form sacks. PE is a lightweight and very tough material, see also ballistic material or humble milk carton? Suitable materials other than plastic filaments include natural fibres, high performance materials (such as carbon and aramid fibre) and metal wire.

die-cut graphics

2011-08-15T20:07:00.002+01:00

Another nice example of die cutting (see also die-cut dinosaur and die-cut designer flowers). In this case the process is used to profile sheets of black and white polyethylene (PE) plastic. The graphic pattern fits together seamlessly to form the slippery underside of a snowboard. Graphics produced in this way will not wear away like print on plastic.  

Image of World Wide Weapon snowboard by K2 

die-cut dinosaur

2011-07-31T11:28:00.001+01:00

Die cutting is a versatile process. It is used to cut all sorts of sheet materials including paper, plastic (see an example of tyvek in die-cut designer flowers), card, wood, fabrics, labels and composites. Mainly used in the mass production of cartons and boxes, here it has been used to profile a flat-pack dinosaur in birch plywood.

The cutting action is between a sharp cutting rule and a steel cutting plate, and therefore results in clean, accurate cuts. 

Image from MPFDP

colour buttons

2011-07-20T18:12:00.000+01:00

An advantage of compression moulding rubber keypads is that it is possible to integrate a range of colours.  Just like colourful recycled plastics, the coloured parts can be moulded in the same sequence, in which case the joint line is irregular.

Rubber compression moulding is used to produce parts with various levels of flexibility. Live hinges and tear lines can be integrated into the design to eliminate secondary operations. Another major advantage of working with rubber is that draft angles can be eliminated so buttons can have vertical sides (no taper). 

Image from The Manufacturing Guides

precise paper models

2011-07-08T18:43:00.005+01:00

Depending on the type of laser, almost any type of material can be cut, etched or engraved – have a look at glowing plastic patterns and edge glow acrylic. Very fine details can be reproduced, such as this paper scale model, because the laser does not apply mechanical pressure to the part, which would distort and break the material.

This is a vector-based cutting system: the laser follows a series of lines from point to point. The files used are taken directly from CAD data. Compatible file formats include .DXF and .DWG. 

Architectural Model Accessories Series by Terada Mokei 

bright metallic packaging

2011-07-02T08:16:00.001+01:00

This beautiful green tea packaging from China looks like gold. It is wrapped in plastic, which has been coated with a very thin layer of aluminium.

Aluminium is highly reflective (up to 95%) and so creates a very bright metallic appearance. It is laminated, printed, welded and vacuum packed just like non-metallised plastic packaging.

Image of TieGuan Yin Tea.

jiggering and piercing

2011-06-25T11:00:00.000+01:00

Ceramic plates, bowls and similar items are shaped using a technique known as jiggering (or jolleying if the mold is in contact with the outside surface of the part rather than the inside surface). Although these processes can be automated, they are still frequently carried out by hand and require a skilled craftsman.

A charge of clay is placed onto a single-sided mould. As it rotates at high speed, the backside (jiggering) or inside (jolleying) are formed with a profiled tool. Parts made in this way must be rotationally symmetrical, but the patterns and decorations are moulded into the surface and so can be asymmetrical. After forming and a short time air drying, the holes are pierced using a profiled punch. 

Image from The Manufacturing Guides    

pink velvet flock

2011-06-22T22:20:00.001+01:00

A flock coating is made up of short and densely packed fibres that are applied electrostatically, causing them to stand on end and feel like velvet. It comes in a wide range of colours, including fluorescent, that appear rich, uniform and matt.

Almost any material can be flocked and patterns are created using flexible vinyl stencils.

Image from The Manufacturing Guides 

stingray leather

2011-06-17T11:33:00.000+01:00

There are many varieties of stingray. Each has distinctive markings and patterns. Saltwater stingray have evolved a tough skin covered with bony plates and tanneries have developed methods for softening the hard-wearing hides to make them pliable.  

Saltwater stingrays are caught for food in many countries. As a by-product of the fishing industry, the skin is used for applications including shoes, boots, belts, wallets and knife handles.

interactive surface

2011-06-14T07:38:00.000+01:00

Used in architectural and interior applications, Sensacell is made up of tiles of LEDs that light-up when you get close to the surface. The reaction is triggered by capacitive sensors. In other words, it is like an ultra low resolution touch screen. 

curiosity-driven design

2011-06-13T22:25:00.005+01:00

A talk at TEDx Thessaloniki, Greece. In the spirit of ideas worth spreading, TEDx is a program of local,  self-organized events that bring people together to share a TED-like  experience. Visit the website

rusty steel

2011-03-25T08:33:00.000Z

Cor-ten is a high-strength low alloy steel. Over time a layer of rust develops on the surface, which protects the raw steel underneath. This eliminates the need for painting or other protective coatings. It is used in architecture and outdoor sculpture, such as the Fulcrum at Liverpool Street Station in London.   

Image from MPFDP

humble beginnings for a water bottle

2011-03-22T14:33:00.000Z

Blow moulded plastic packaging, such as water bottles, are made by injection moulding a preform and then inflating it with air inside a mould. Injection moulding ensures that mechanical features, such as the screw thread, are reproduced precisely. Blow moulding is used to produce high volumes of parts with thin wall sections. This reduces the total amount of material used. 

injection moulded wood

2011-03-19T09:16:00.000Z

Biocomposites are mouldable materials made up of natural fibers (commonly wood) bonded together with either natural or synthetic adhesives. These materials provide an outlet for agricultural by-products and industrial waste such as wheat straw and recycled newspapers.

The Treeplast golf tee is made up of 50–70% wood, crushed corn and natural resins. The material can be processed with conventional moulding equipment and is fully biodegradable.    

Image from MPFDP

dip moulding

2011-03-14T20:37:00.000Z

This is a simple process used to make products such as rubber gloves. A hot metal tool is dipped into a bath of plastisol. The liquid gels on the surface of the tool to form a layer of polyvinyl chloride (PVC). This is a one-way reaction.

The environmental credibility of PVC has been under investigation in recent years due to dioxins, harmful organic compounds that are given off during both the production and the incineration of the material. 

Image from The Manufacturing Guides

polyester mesh knit

2011-03-12T07:32:00.002Z

Upholstery fabrics made from polyester can withstand extremely heavy use. In this case the mesh knit front face is laminated to a tricot backing layer to produce a hard-wearing and colourful upholstery textile. Polyester fiber is light, durable and produced in bright colours. As well as being used for everyday consumer products, like sports apparel and clothing, it is utilised for industrial applications like ropes, netting and reinforcement for car tyres. It is used alongside aramid and carbon fibers to strengthen 3D thermal laminated lightweight racing sails. 

lightweight racing sails

2011-02-19T14:01:00.009Z

3D thermal laminating (3DL), was developed by Luc Dubois and J. P. Baudet at North Sails in 1990 and has since been adopted by nearly every racing boat in the Volvo Ocean Race and America's Cup. 

Sailmaking has been transformed by 3DL. Instead of cutting and stitching patterns to create the ideal 'flying shape', strength to weight is maximised by laying continuous strands of fibre reinforcement (aramid, carbon and polyester) along the pre-determined lines of stress. Sandwiched between thin sheets of polyethylene terephthalate (PET) the individual fibres are bonded in place with a specially developed adhesive. 3DL sails give racing boats huge competitive advantage: they are seamless and up to 20% lighter than conventional equivalents.

Image from North Sails  

cast acrylic

2011-02-12T17:59:00.003Z

This is another really nice example of edge glow, or live edge, but this time in a block of cast acrylic. This material is used for interior applications and trophies for example. It is possible to cast 3D shapes, or laser cut a profile from sheet.  

The cast PMMA (poly methyl methacrylate) has been doped with a fluorescing dye. So in ambient lighting the block appears to light-up and glow. 

nanotech aerogel

2011-02-05T09:28:00.002Z

Nanomaterials are characterised by their very small size, which is typically around a millionth of a millimeter. Materials this small are built from the bottom-up, at an atomic level, as opposed to conventional top-down manufacturing.

Nanomaterials have been in use for many years. Early examples include the use of gold nanoparticles in stained glass windows to produce red colouring, and titanium dioxide, which is the white pigment in paint, toothpaste and a range of cosmetics.

This is Aerogel, developed by NASA and manufactured by JPL. It is incredibly light and 99.8% atmosphere. Like ordinary glass, it is fragile and brittle, but it is a much more efficient thermal insulator because the internal structure has vast surface area. There are not many commercial applications outside aerospace. However, in 2007 Dunlop Sports released a range of tennis rackets with an aerogel core. Its extreme lightness is used to produce a racket with high strength to weight and stiffness.

Image from NASA/JPL

light and colourful plastic panels

2010-12-24T09:53:00.000Z

These composite plastic panels – produced by Bencore - are bright, colourful and lustrous. They are produced by high-pressure  laminating and are suitable for furniture and interior applications such  as tables, walls and floors.

Both the  structural cylindrical core and tough outer sheets are polycarbonate (PC). An  amorphous polymer (unorganised and non-crystalline molecular structure),  PC has excellent clarity, is tough and resistant to impact. It can be produced in a range of vivid colours.  

Image from MPFDP 

product and furniture design

2010-12-19T10:52:00.003Z

Now shipping... "This book, part of a new series built on the authority of Rob Thompson's highly acclaimed Manufacturing Processes for Design Professionals, includes new content selected specifically for the needs of students who create product and furniture designs for mass production. With some 450 specially commissioned photographs and technical illustrations, it describes more than 30 manufacturing processes, from the traditional and established to cutting-edge technologies." Amazon UK and US 

prototyping and low-volume production

2010-12-19T10:49:00.001Z

Now shipping... "Part of a new series built on the authority of Rob Thompson's highly acclaimed Manufacturing Processes for Design Professionals, this book features new content selected specifically for the needs of students who create prototypes, designs for low-volume production runs, and designs that utilize craft. With some 450 specially commissioned photographs and technical illustrations, it describes more than 30 manufacturing processes, from the traditional and established to emerging technologies." Amazon UK and US 

forced red rhubarb

2010-12-14T23:18:00.000Z

Forcing rhubarb by growing it in warm and dark conditions causes the young shoots to grow rapidly in search of light. This contributes to the fantastic, fresh red colour of the stems.

supersonic water jet

2010-12-11T18:38:00.000Z

Water jet cutting can be used to cut and profile almost any type of material from soft foam to titanium. The supersonic jet of water, forced from the cutting nozzle at pressures up to 4,000 bar (60,000 psi), will cut through 60 mm of stainless steel. The process is computer-guided so hard materials – like marble, ceramic and glass – that are usually difficult to work can be cut into intricate and complex shapes directly from CAD data. 

Image of water jet cut glass cubes.     

rubber-cased perfume packaging

2010-12-06T09:58:00.003Z

Thermoplastic polyurethane (TPU) is naturally clear and available in an almost unlimited range of colours. It is soft and resilient, which means it can be stretched, pulled and twisted without breaking. In fact, it's strong enough to be used as the outer cover on golf balls, which are hit so hard they travel at speeds of more than 100 km/h. The opportunities of these qualities for designers are neatly captured by Curiosity Inc. in the Fue D'Issey perfume bottle packaging.

Image from MPFDP 

bamboo in black resin

2010-12-03T19:30:00.003Z

Bamboo is a distinctive material. Several species have similar properties to hardwood. But it is faster growing and can be harvested every four years or so, making it a relatively sustainable and low  cost alternative. It is strong, light and can be machined and joined just like conventional hardwoods. 

China is the largest producer of bamboo and has used it for construction and furniture for thousands of years. Now its popularity is growing elsewhere and it is being widely used in applications like furniture, flooring and tableware.

Detail of a cast resin chair by Mandala. 

bending wood veneer

2010-11-10T19:13:00.002Z

 
The minimum internal radius of a bend in wood veneer is determined by  the thickness of the individual veneers, rather than by the number of  veneers or thickness of the lay-up.

Veneer laminating is generally limited to single axis bends. However, shallow dish shapes are possible, like the seat of the Flight Stool, and the Danish company Cinal (now owned by GUBI) developed a unique bending and layering technique that makes it possible to produce much deeper dish profiles.

Image from MPFDP

edge glow acrylic plastic

2010-11-03T06:29:00.000Z

The edge of clear tinted plastic appears to glow in ambient lighting. The phenomenon, known as "edge glow" or "lit edge", is caused by light waves being refracted internally and transmitted out through the laser cut edge, rather than the surface. The effect is enhanced by fluorescent pigment.

Scored and etched lines on the surface of plastics cause the same effect - see glowing plastic patterns. This is utilised in signage to illuminate graphics whilst keeping the light source hidden. 

Image of laser cut acrylic (poly methyl methacrylate).

extruded glass profile

2010-10-29T12:21:00.000+01:00

The ethereal and precious qualities of glass captured in a continuous extruded profile. It seems amazing that it's possible to harness these high value qualities in a process usually associated with plastics and metals. Simple tube profiles over 400 mm diameter are feasible but complex and intricate profiles can't be made so large. Used in the production of scientific equipment and even building facades, there is a great deal of scope for such materials.

Extruded glass is typically borosilicate, which is also known under the trade names Duran, Simax and Pyrex (although the Pyrex consumer brand no longer uses borosilicate glass in North America). Borosilicate is used primarily for its resistance to high temperatures and thermal shock.

Image from MPFDP

a stack of paper pulp packaging

2010-10-25T17:21:00.001+01:00

One factory's waste becomes protective packaging for delicate goods. Molded pulp packaging can be made entirely of waste material from the paper industry. The process by which it is manufactured is reasonably environmentally friendly as the recycled material needs only the addition of water. It is naturally grey or brown, depending on the raw material. Brown pulp is typically made up of high quality craft paper, whereas grey pulp is composed of recycled newsprint and is not quite as sturdy or resilient. 

Image from MPFDP

lightweight laminated wood

2010-10-20T19:38:00.003+01:00

There is nothing new about the process of bonding two or more layers of wood veneer together to form a laminate. However, as a result of developing stronger, more water-resistant and temperature durable adhesives, lighter and more reliable structures can now be engineered in laminated wood and so greater creative opportunities have arisen in design and architecture.

Image of a partially finished Flight Stool designed by BarberOsgerby from MPFDP

structural and decorative wood veneer

2010-10-19T20:15:00.004+01:00

Any timber can be turned into veneer and used as a structural laminated material, or simply applied for decorative effect. The wood must be free from defects, such as knots, to ensure an even grain. The most flexible timbers include birch, beech, ash, oak and walnut.

Veneers are produced by cutting very thin strips of wood 1–5 mm thick from logs. They are either peeled continuously around the circumference of the log (rotary cut) or cut across the width of the log (so the grain runs along its length).

laser cut plastic patterns

2010-10-16T18:10:00.001+01:00

Just like glowing plastic patterns this 3 mm thick plastic was shaped by laser cutting. The laser beam is focused through a lens that concentrates the beam to a fine spot between 0.1–1 mm. The high concentration beam melts the material on contact. The laser  beam cuts and polishes the acrylic in a single pass, which produces an  excellent finish even with intricate profiles and fine details. 

Laser cutting machines work directly from CAD data. This means that data can be translated very readily from a designer’s computer onto the surface of the material. As a result this technology can be utilisied for everything from one-offs to mass production, such as architectural models (see precise paper models) and the Queen Titania light by Luceplan.    

colourful recycled plastics

2010-10-14T23:01:00.002+01:00

These colourful Smile Plastics sheet materials are manufactured by compression molding. They are made up of thermoplastic materials, which are very efficient to recycle and there is minimal degradation of quality.

Chips of recycled industrial and post-consumer waste – including packaging, footwear and even old mobile phones – are placed into a mould, heated and compressed. The different-coloured materials meld together but do not mix completely during heating and so retain a trace of their previous life. 

Image from MPFDP 

mass-produced one-off?

2010-10-08T05:47:00.001+01:00

I one-offed these mass-produced plastic containers in a dishwasher: the temperature was just high enough to distort the thin wall sections but not melt them completely. The concept of creating individual pieces on a mass-production line has led designers to experiment with and challenge conventional engineering practices. Although I cannot think of one good example of a mass-produced one-off there are many examples of designers harnessing industrial processes to create individual and personalised decorative objects such as Tord Boontje's flower light and my material memories. However, there are certain manufacturing processes that lend themselves to creating products with random colour and surface effects. More on that to come...   

bright anodised aluminium

2010-10-06T05:31:00.000+01:00

Anodising is used to strengthen and protect the surface of aluminium.  It is an electrochemical process that builds up a layer of super-hard  alumina on the surface of the material. Bright and metallic colours are  created by dyeing this porous ceramic surface layer in a process known  as 'dip and dye'. It is widely used in premium consumer products due to  the durability and metallic feel of the colour. It is possible to  anodise and colour all types of surface finish from bright polished to  blasted and brushed.

Image of anodised aluminium colour swatches

curly wood shavings

2010-10-04T07:11:00.001+01:00

Another example of one factory's waste being used as a raw material somewhere else see previous post. In this case wood shavings – manufactured from scrap timber or a byproduct of construction and furniture making – are used as a packaging material to protect delicate goods during shipping.

Image from MPFDP

fluorescent and reflective

2010-09-29T22:46:00.000+01:00

Fluorescence and reflectivity have been utilised by the military, industrial workers, cyclists and signage for sometime to highlight and draw attention to things. Due to technical advances and more durable dyes these phenomena have become ubiquitous to the point that we hardly notice anymore.

Fluorescent materials glow brightly because they absorb light in the ultraviolet portion of the spectrum and emit light in the visible potion. Therefore, the surface of the material will appear brighter than its surroundings, because it is emitting more visible light. Other than the obvious applications this quality is also utilised more subtly, for example in white paper, textiles and washing detergents to make colour appear brighter.

material memories plastic stools

2010-09-27T05:47:00.000+01:00

These stools have a deep surface layer of recycled materials. Over time they slowly wear and the patterns change according to how the furniture is used. Taking advantage of the irregularities in the manufacturing process, each product is visually unique from the outset. The goal was to manufacture plastic objects that connect  emotionally with the owner in a similar way to natural materials like  wood and leather. 

glowing plastic patterns

2010-09-25T11:51:00.003+01:00

Laser cutting machines are mesmerising to watch in operation. It is a computer-guided process – data is inputted and the machine runs its course – known as computer numerical control (CNC). One of the many advantages of CNC is the ability to produce extremely accurate parts to precise tolerances.

The scored lines created by the laser cutter appear to glow, an effect known as 'edge glow'.  This is caused by light picked up on the surface of the sheet and  transmitted out through the edges. The scoring acts like an edge and so  lights up in the same way, accentuated by the fluorescing yellow tint.

Image of pattern designed by Ansel taken from MPFDP 

liquid light

2010-09-24T06:18:00.000+01:00

A nice twist on the conventional pendant light: this blown glass vessel is filled with gin and tonic, which glows when exposed to ultraviolet light. The fluorescent effect is caused by the small amount of quinine in the tonic. 

Sapphire Light by Paul Cocksedge.

wood: a natural antibacterial

2010-09-23T06:58:00.001+01:00

Data collected by Dr Dean Cliver demonstrate that wood is naturally antibacterial and so is ideal for applications like kitchen surfaces and chopping boards. Didn't we know that already..? Apparently not, as the report begins with "We began our research comparing         plastic and wooden cutting boards after the U.S. Department of         Agriculture told us they had no scientific evidence to support         their recommendation that plastic, rather than wooden cutting         boards be used in home kitchens." Read more about the study here

Image of fruitwood chopping board from MPFDP

the colour of stainless steel

2010-09-21T06:32:00.004+01:00

The surface of stainless steel can be chemically altered to produce a range of rich colours. Similar to some birds' feathers and butterfly wings the colour is caused by light interference at nano scale. Known as interference or structural colour, it shifts and changes according to the viewing angle, because the light waves are split and refracted in all different directions.

Image of architectural cladding by Rimex.  

chestnut leaf packaging

2010-09-19T10:09:00.001+01:00

Other than the heritage of wrapping Banon cheese in chestnut leaves they help to keep it moist and contribute to its distinctive flavour by imparting a little tannin over time. This relationship was likely established before paper-making was even known and has remained intact due to the many functions the leaves perform that cannot be recreated with man-made materials.   

Thanks for the picture Lina

die-cut designer flowers

2010-09-18T08:14:00.006+01:00

Layers of coloured tyvek (tough non-woven polyethylene sheet), shaped by die cutting, draped over a light bulb to diffuse the light. This is nice example of reinterpreting an industrial process for a decorative object. Die cutting is used to make packaging, promotional materials and stationary products: in most cases it is simply the most efficient way of making cutouts in sheet materials that are subsequently folded, assembled and glued together. Whereas for this lampshade it is the fundamental process and utilised for both functional and decorative purposes. 

Midsummer pendant light by Tord Boontje. 

fashioning gold from wood

2010-09-17T06:25:00.001+01:00

Imagine  carving solid gold. Well, the same effect has been produced here by  carving wood and coating it with a layer of gold by electroforming. It  is possible to build up the thickness of the gold to several millimeters  or until it becomes self-supporting. Many types of metal can be  applied as 'coatings' in this way. Used in the production of finely  detailed film props, like armour and masks, it is the  most practical way of reproducing such intricate parts in metal.

Image from MPFDP 

bright and colourful aluminium

2010-09-15T07:10:00.001+01:00

Aluminium is a bright and reflective material. The colours in this light are made by changeable filters covering the bulb, rather than colouring the surface of the aluminium by anodising.

Queen Titania pendant light by Alberto Meda and Paolo Rizzatto for Luceplan.

structural colour

2010-09-13T06:23:00.000+01:00

The shimmering and vivid colours in some birds' feathers are caused by light interference at nano scale. Pigments are colourful due to absorbing light waves. By contrast, structural colour is caused by the surface of the material splitting and refracting light waves. The colour shifts according to the viewing angle and creates the bright shimmering effect, which is most dramatic in peacock feathers and butterfly wings. 

wood: a natural composite material

2010-09-11T13:29:00.004+01:00

Wood is made up of lignin and cellulose. To make the wood adequately pliable for steam bending, the lignin, which bonds the cellulose chains together, must be softened (plasticised) to reduce its strength. This is achieved by steam treating the wood in a pressure chamber.

When the ligning becomes plastic the wood will compress very readily, but will break when stretched by more than about 1%. Therefore, bends are formed by compression.

Part of a bentwood coat stand by Thonet. Image from MPFDP 

alumina's distinctive appearance

2010-09-09T12:51:00.000+01:00

Technical ceramics – extremely durable, hard and resistant materials – are shaped by pressing and sintering. After pressing it is possible to CNC machine parts accurate to a few microns. Raw ceramic has a beautiful feel and appearance unlike any other material.

ballistic material or humble milk carton?

2010-09-05T10:40:00.003+01:00

Polyethylene (PE) is an exceptional material. Not only is it used to make a wide range of everyday products, like milk cartons and plastic bags, it is used as a ballistic material by the military for its exceptional resistance to punching and tearing.

DSM developed Dyneema in 1970s. It is classified as an ultra high density PE (UHDPE): as a drawn fibre it is up to 40% stronger than DuPont Kevlar; as a sheet material it is 15 times stronger than steel. Laminated sheets 25 mm thick provide ballistic protection for armoured vehicles.  

Image from MPFDP

waste or raw material?

2010-09-02T22:45:00.001+01:00

One factory's waste is another factory's raw material. These one tonne bales of scrap card are a by-product of manufacturing cardboard boxes. The card is shredded, mixed with water and moulded into paper pulp packaging. At the end of its useful life the moulded pulp can be recycled all over again.

wood knive, fork and spoon

2010-08-26T21:59:00.002+01:00

Pressed from birch, they are light, cheap and biodegradable. Birch is a relatively fast growing deciduous tree that can reach heights of around 30 m. It grows across North America, Asia and Europe. It is strong, durable and inexpensive. Alternatively, species of poplar, or aspen, are used to make these types products.

Wood is a naturally antibacterial material and certain types, like birch, are almost tasteless, making them ideal for products like toothpicks, disposable cutlery and toys.  

Image from MPFDP

cooking with technical ceramic

2010-08-23T19:29:00.001+01:00

The ceramic ball inside Jamie Oliver's Flavour Shaker uses materials and manufacturing associated with extreme applications in the aerospace, military and automotive industries. Alumina is one of the hardest and most durable high performance materials. The powder is formed into shape using high pressure and sintered at high temperature. This produces an extremely dense, stable and resistant material.

Image from MPFDP

inspired by nature: the lotus effect

2010-08-21T09:56:00.003+01:00

Beads of water form on the surface of a leaf. This phenomena was discovered on the Lotus plant and patented by the botanist Wilhelm Barthlott. The natural self-cleaning properties of the leaf are produced by a microscopically rough and super-hydrophobic surface.  The surface tension of the water is greater than the adhesion strength to the surface of the leaf, resulting in the formation of droplets that roll off and pick up dirt along the way. Biomimetic nanotechnologies, including coatings, paints and surface treatments, have been developed to mimic the lotus effect on clothes, products and buildings façades.

lightweight wooden packaging

2010-08-18T06:48:00.014+01:00

Poplar wood cut into thin strips and assembled into packaging for cheese and chocolates. It is an inexpensive, fast growing wood used widely in furniture and toy making, paper production and the cores in plywood and composite laminates. It is lightweight, flexible and resistant to splitting, so thin sheets can be bent into tight curves.

Image from MPFDP 