ARC640 Relational Geometries

Casting with Curvature


The diagram above show the layers of the framework for the molds. The bottom waffle support layer gave the desired curvature needed to create the surface deformation. The middle layer supported the silicone molds spanning the waffle supports. The silicone molds were then filled with the ultracal which is shown in the videos below.



Acrylic mold | Silicone pulled out of the acrylic mold | The silicone mold for ultracal


Ultracal pour | Cured pour in mold | Ultracal pulled out of mold

The video above shows the pouring of the ultracal onto the silicone molds placed on the framework to achieve the desired curvature.

The video above shows the demolding process of the ultracal out of the silicone mold. The fluid nature of the ultracal during the casting process creates a precise cast.


Demolding the ultracal


Panels stacked on top of each other


Ultracal panels in series


Ultracal panels in series

Night Lighting Studies


.048 Panel


.063 Panel


.091 Panel


.122 Panel

Daylighting Studies


.122 Panel


By performing light studies, certain variables affect the amount of light that penetrates through the assembled panels. These include:

  • depth of material
  • size of aperture
  • angle and strength of lighting
  • curvature of surface

The original intention was to create an aggregate unit that could be tiled as a system. By using silicone as a mold material, it was limited by the way the molds deformed on the curved surface. The study was modified to create four sets of panels that have different apertures and curvatures.  The extent of the surface curvature was also limited by the molds ability to hold the ultracal in its fluid state. Improvements to the study could be to revamp the casting surface or by incorporating jigs to firmly secure the silicone molds to ensure that adjacent tiles align correctly.