Endterm

Hair extension heat tool / melting

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After a lot of testing and melting of synthetic thread I found that polypropylene works best

Lasercutting / setting adjustment / melting

Soldering tool / metal station / corner melting

Soldering tool / metal station / melting

Soldering tool / metal station / using metal as a "glue"

Soldering hand tool / using thread instead of metal to solder

Soldering / metal station
using thicker thread and other colors

Soldering with thread instead of tin / metal station
using contrast in colors

Soldering / metal station
using metal more prominently

Polypropylene is a type of thermoplastic polymer resin. According to some reports, the global market for this plastic is 45.1 million tons, which equates to a consumer market use of about $65 billion.

This material is used in products such as the following:
*Plastic parts - from toys to automobile products

*Carpeting - in all forms of carpeting, area rugs and in upholstery

*Reusable products - especially in containers and similar products

*Paper - used in various applications for stationery and other writing bindings

*Technology - commonly found in loudspeakers and similar types of equipment

*Laboratory equipment - in virtually every aspect where plastics are found

*Thermoplastic fiber reinforced composites

I
--> Needs more heavy stability:
combine tin soldering with soldering without binding material

Ends up more sturdy and heavy so that objects can actually be placed in the basket

Pattern model making and experimenting
Seeing what pattern is sturdy, playful and aesthetically pleasing

Melted sides

Fully melted connection point

POSSIBLE PRODUCT FUNCTION: TOY BASKET

--> As the similar name might suggest, polypropeylene (PP) features similar properties to polyethylene; both are polymers, but the former comes from propylene instead rather than ethylene. As a cheaper alternative, there are some benefits associated with choosing this polymer in toy manufacturing, but it's not without drawbacks; polypropylene varies considerably in durability, so a cheap toy that uses it might actually just be a cheap toy.

I wanted my polypropylene basket to store away items that would enforce my concept, PP is regularly applied in the making of toys which is why I chose this storage product. The clear difference between the toys and my basket is that the toys aren't durable or sustainable while my melted basket is an inventive encouragement towards a more sustainable recycling and production process. By storing away short-lasting products it almost guarantees a longer durability as you would take better care of them.

After researching what toy baskets are already on the market (examples or visible below), I can conclude that they are very simplistic, rustic-looking, have faded colors, are plain, etc. Designs like these probably won't motivate children to store toys, it isn't a joyful experience for them. I believe that playful and colorful design will motivate them and make it a pleasurable time for them rather than the end of a fun moment.

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Is PP safe for humans?
Considering I want my design to be available for kids and adults I definitely don't want to use a toxic plastic that could endanger the their health when in contact with the product.

Research:
Polypropylene (PP) is usually considered safe for humans. It is considered the safest of all plastics; it is a robust heat-resistant plastic. Because of its high heat tolerance, it is unlikely to leach even when exposed to warmth. Only when in contact with the powder consistency or the molten material it can cause potential health effects. Luckily my basket consists none of these, the only possible health effects are caused by the ingestion of the material. Although not probable, ingestion of PP may produce mild gastrointestinal irritation and disturbances. As my basket is well binded this is unlikely to happen.

MEASUREMENT RESEARCH:

I looked into the general measurements of toy baskets on the market at the moment. Afterwards created an average, that I would apply to my toy basket.

Basket 1: Height 31cm, Length 44cm, Width 39cm
Basket 2: Height 28cm, Length 39cm, Width 39cm
Basket 3: Height 22cm, Length 37cm, Width 25cm
Basket 4: Height 58cm, Length 37cm, Width 47cm
Basket 5: Height 32cm, Length 37cm, Width 32cm

CHOSEN MEASUREMENTS FOR MY MELTED BASKET:
Height 35cm, Length 40cm, Width 40cm

+ an extra 10cm for design play

TRYOUT 1:
I made this pattern in real life and size but wasn't too pleased with the way the rope moved and folded. I think this structure isn't a good one for the connections and is generally not what I'm looking for. It looks too messy and takes away from my wanted focal point, the melted connections

Trying a less complicated pattern and building in 3D rather than starting from 2D. I am trying to see if it holds its form better three dimensionally and looks cleaner.

Non melted basket attached with iron wire to get an idea of the final frame

Photography inspiration board

Soldered basket, with fluffy ends everywhere

I decided to remove the fluffiness to the horizontal pieces of rope as I find it distracting and it takes away from the grid

Final product

The Melted Basket

How do I achieve a controlled, contrasting, and playful design by just using one material and tool?

After having a good time playing with toys or cuddling up in a blanket, it's time to put them back into my molten basket. It all started with my interest in the heat of machinery rather than its original function. Exploring different machines that aren’t necessarily used for heat such as the 3D printer and the lasercutter was a real challenge. The synthetic thread samples were hard to control but the concept had potential and I was not ready to give up. Striving for more control I started looking into actual heat machinery such as a soldering iron and a hair extension iron. Finding the perfect synthetic thread and a good soldering approach eventually resulted in interesting samples. The better the results got the more my final product started gravitating towards a not-so-ordinary basket. Playing with the flexibility of synthetic thread, I developed these strong woven grids, which I turned into a toy basket to portray the essence of my technique in a clear but playful manner. It results in these intriguing contrasts in the structure of the thread. The poly-propylene thread is melted together with a soldering iron at specific points to construct these connections without the use of any binding material, allowing the basket's overall grid to remain flexible and adaptable. Its playful shape does not interfere in its practicality, as it makes storing many items enjoyable and vibrant. The process for creating this solid basket is durable and will simplify the recycling process of polypropylene.

I was driven by my fascination with the heat of machines and how it may transform your material. I chose a material that I knew would react to heat, which is synthetic thread, more specifically polypropylene thread. My approach was not simple since controlling machinery such as the 3D printer and lasercutter was difficult and created irregular results. I began experimenting with heat-generating tools such as a soldering iron and a hair extension iron. Once you understand how they work, they are lot easier to handle. I was able to make solid connections with polypropylene thread using simply heat. Each machine produced intriguing samples that I could absolutely include into my final technique and product. My tool would have to be chosen based on the thickness of the PP thread I end up using for my product. I discovered that working with the hair extension iron was easier when using thin thread and more difficult when using thick thread because it isn't powerful enough. Finally, I chose to create a large basket, which required the use of a soldering iron for the best and cleanest results.

Finding out what the different qualities of the poly-propylene thread were by using various machines and seeing how the material reacts to them. Melting the thread and comparing all my samples to develop a final technique.

Seeing if I can create two-dimensional and three-dimensional products with this initially flat material.

Create patterns and grids that will be strong but won’t take away from the flexibility of the PP thread.

*The ability for my product to be solid but aesthetically pleasing

*Visually create a clear contrast between the woven thread and the connection points

*Don’t use binding agents

*Be playful and colorful

*Hands-on work which will be noticeable in the end result

*Create a three-dimensional product

I find my alternative soldering technique to be quite relevant as it is an inventive and durable way of binding polypropylene plastic. My method simplifies the recycling process of the plastics since there is no binding agent incorporated. I worked critically by trying various heat machines until I was pleased with the qualities of my samples. I find my ability to connect thread without a binding material to be one of the strongest aspects of my process. The connection points are solid but don’t take away from the flexibility of my melted basket. Although the application of my technique isn’t as developed as I would want it to be, I am pleased with how my soldering process is applied onto my final product. It portrays the properties of my method very well although I would’ve enjoyed making multiple ones if time allowed me.

What tool will give me the best melting result?

Project Abstract

Relevance

Key experiments

Research approach

Design criteria