Having worked out the correct fold to create the Stjerne coffee table I turned the fold into full scale. Using paper at this point was a no go as the resin that I would use to create the mould would ruin the shape. The final shape was folded out of PVC seen here below.
Obviously Stjerne was not a self supporting shape like some of my designs so a brace had to be put in place to hold the form. The fibreglass was then laid on to freeze the shape for later use
Pardon the dreadful photo but it shows the first table base out of the mould and the mould sitting next to it. Both created wonderful tables and the mould side (with the corners pointing upwards) fitted the glass I had accounted for perfectly. Sadly though with concrete having it’s strengths in compressive dimensions the pressure of levering out each corner created tiny aesthetic cracks in the shape so I was not able to use it that side up.
In contrast though the other shape was so strong that whilst it was only a few mm thick I could quite easily stand on it and not break it
When It came to moulding Kronen the process was slightly different as the product was more than a one peice mould. You can see from the maquette that the piece is made from one fold at the bottom and more attached to the top.
This meant the to create the master I had to replicate that but weight became a factor with the increased material causing the shape to distort. My solution was to create a brace where the 2 parts met and bond them to it which worked fine.
The mould was then laid up from the inside and was obviously not very rigid to start, but with layers of gel coat applied it held its form while the gel coat set and became stronger each layered. Once the gel coat was thick enough it was backed with fibreglass to make the final master.
This master was then moulded using a traditional fibreglass mould technique and comprised of 9 sections.