In the run-up to the project, I observed and supported the master carpenter Jens Weickardt in his work for one week. The aim was to design a useful object for the cooperation partner during the semester.
While repairing a handrail during the observation phase, the two-component polyester wood filler was coarsely applied to the damaged area by a carpenter and, after curing for twenty minutes, roughly worked with chisels and painstakingly sanded into shape. The aim of this work is to simplify the process.
Depending on the size and shape of the defective profile, different profile forming tools are advantageous. The ProfilBox combines them.
The mould is taken off at an undamaged place. The tools are pressed onto the applied filler and fixed. Excess material is removed immediately and the tool effortlessly after curing. This means that there is only little need for regrinding.
Based on the functional principle of a shape gauge, I developed the Profillehre, which is particularly suitable for fine-stepped profile parts. It consists of a stack of uniform and one millimetre thick polyethylene sheets held together by a frame.
Polyethylene and polypropylene do not combine with other plastics or adhesives and are very easy to remove from the polyester filler. I have optimized the shape of the panels for tight spaces.
Threaded rods, wing nuts and flat steel profiles keep the surfaces stable in any position. Fine steps in the filler can easily be sanded down or avoided by placing a silicone film underneath.
The Formfläche picks up the principle of a curve ruler. It can be shaped by hand and is particularly suitable for large profile shapes such as those found in handrails.
After extensive research, I decided to use Formetal Ypsilon as a stabilizing component, as it can be shaped very often and easily by hand in three dimensions and in a limited frame without any signs of fatigue.
This is embedded in thin layers of silicone, which can be easily separated from the filler.
The Vakuumkissen is inspired by an industrial robot gripper arm. The stretchable, flexible, 0.5mm thin silicone surface stiffens with the help of the hollow glass ball filling, from which the air is extracted. Thus it retains the given shape.
I optimized the grain size, material thickness and cushion shape several times during the process. Initially planned casting channels proved to be impracticable.
The Systainer, which is equipped with tool holders, integrates the tool seamlessly into the existing workshop equipment and can easily be taken along for use by the customer.
project in cooperation with master carpenter Jens Weickardt semester project Auf Arbeit supervised by professor Vincenz Warnke overall documentation Auf Arbeit.pdf fourth bachelor semester industrial design