Fundamentals of Digital Fabrication

An overview of my journey into various digital fabrication technologies, where I'm expanding beyond my experience in 3D printing.

In the Digital Fabrication course, we're exploring a wide range of digital manufacturing technologies. Although I’m well-acquainted with 3D printing, this course introduces new methods like CNC machining, laser cutting, basic electronics with Arduino... I’m excited to gain hands-on experience with these tools and broaden my design and fabrication skills.

Introduction to the wood workshop area

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3D printed tiles design for molding

For our first project, we were tasked with creating personalized 3D-printed tiles in pairs, which we’ll later use to make molds for casting tiles. My partner Kevin and I decided to personalize our tiles by incorporating 3D scans of our faces.

To scan my face, we used photogrammetry, taking around 150 photos with a mobile camera. These photos were imported into Metashape, where the software aligned the images to generate a 3D mesh. Afterward, we refined the mesh in Meshmixer and imported it into Rhinoceros, adding a base to finalize the tile as a solid piece. For Kevin’s tile, we used a mobile app that yielded a surprisingly detailed result, proving to be a fast alternative to the more complex Metashape process.

Me in the Metashape program

Once our designs were finalized, we set up the tiles for 3D printing. To achieve a high level of detail and reduce the need for supports, we oriented the tiles vertically and faced the relief downward. We printed them using the Zortrax 200 printer, which allowed me to get familiar with a new brand and slicing software, Z-Suite. This setup helped us achieve good definition on the facial features and ensured a smooth printing process.

Preview of the printing in Z-Suite

3D printed tile with my face

We used a laser cutter to create a cardboard box model cut into pieces, which we then assembled into a mold structure. This box served as a frame for attaching the tile we had previously printed. Once secured inside, the tile acted as a positive design, shaping the final mold. The assembled structure was ready to be filled with silicone, creating a negative impression of the tile's design.

Laser cutting machine

Assembly of the mold box

To prepare the silicone, we mixed its two activating components thoroughly before carefully pouring the mixture into the mold. The pouring process was done slowly, starting from the base of the tile to minimize the formation of air bubbles. After filling, we applied vibrations to the mold to further eliminate bubbles and ensure an even surface. Once cured, the silicone mold was successfully removed, capturing the negative imprint of my face tile and setting the stage for the final casting process.

Measure and mixture of the silicone

Silicon pouring in the mold

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Tile Fabrication with Cement

For the first tile, we worked with cement, a straightforward and durable material. The process involved mixing cement powder with water until achieving a smooth, consistent texture. Once the mixture was ready, it was carefully poured into the silicone mold we prepared earlier. After filling the mold, the tile was left to cure and harden, resulting in a sturdy and solid piece ideal for the mural.

Mixing

Pouring

The cross for locating the pinwood

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Tile Fabrication with Pine Resin

For the second tile, we experimented with a pine resin-based recipe, a more sustainable and creative alternative. Below is the recipe and process we followed, scaled up to fill the entire mold:

Ingredients:

Ingredient	Amount Used	Purpose
Pine Resin	135g	Base material for structure
Alcohol	45ml	Solvent for the resin
Carnauba Wax	15g	Adds flexibility and gloss
Sawdust (recycled)	120–180g	Bio-filler for consistency

Materials

Result

Process:

1. Melting the Resin The pine resin was melted over low heat and combined with alcohol, ensuring a smooth blend.

2. Incorporating the Wax Once the resin was fully liquefied, carnauba wax was added, stirring until completely integrated.

3. Adding the Filler Gradually, recycled sawdust from the wood workshop was mixed in, adjusting the amount to achieve a paste-like consistency.

4. Pouring into the Mold The mixture was poured into the silicone mold and left to cool and solidify, creating a bio-composite tile with a textured, earthy finish.

Pine resin

Mixing

Pouring

This process showcased the versatility of natural and recycled materials, aligning with sustainable design practices. The resulting tile added an organic aesthetic to the project while repurposing workshop waste effectively.