How many different tools are needed 8 How many parts are standard and bought. 7 How many parts have been made tailored 0 BOTTLEHOLDER2011
1 CUTTING THE SHAPES Download the illustrator file of the website. If you have access to a laser cutter, you can send this illustrator file to the cutter which will cut the desired form. The bounding box measurements of the file are 418x307mm. If you don’t have access to a lasercutter, download the pdf-file. Draw or stick the pattern on to the material and use a figure saw or a jig saw to manually cut out the shapes. Another option is to order your design through a internet service called Ponoko USA (http//www.ponoko.com). This will cost you € 30 and you need the svg-file. Illustrator File in ADDENDUM 1 Lasercutter: 15 minutes / manually: 3 hours Lasercutter / figure saw or jig saw Standard plate of Polypropylene(2mx1mx3mm) One part, the plate, has been added This action costs 14 euro. BOTTLEHOLDER2011
2 NUMBERING THE PIECES Next it’s best to write down the numbers, found on the second pdf-file, on to the different shapes. This way it will be easier to determine the sequence when you start putting the pieces together TIP: It’s best to leave the plastic foil on both sides of the polypropylene plate until the end of the process. That way you can write on this foil and you will get the cleanest result. Numbering and naming in ADDENDUM 2 5 minutes Marker (alcoholic or other) There are no standard parts bought No parts have been added This action costs 0 euro. BOTTLEHOLDER2011
3 CLEANING THE PIECES To get a nice-looking finished result, you can smoothen the shapes by polishing or sanding them with a very fine grain. Do not use coarse or harsh materials to sand the shapes, for this will create scratches into the material! TIP: polishing with a machine will go faster, but be careful that you don’t remove to much material. There is no technical plan of this part. 20 minutes with tools /1 houre without Which tools are used in this action No parts have been added This action costs 0 euro. BOTTLEHOLDER2011 There are no standard parts bought
MAKING OF CURVATURE MOLD Take a piece of wood (thickness ±2 cm) (preferably left-over piece, because you only need a piece of 300x150mm) and stick the pattern (pdf-file: addendum 3) onto it. To create the two smaller holes, use a drill with a diameter of 25 mm. TIP: It’s best to drill a smaller hole first. For the larger hole, use a core drill with a diameter of 90 mm. Now place the 3 pipes in their correct position. Technical Drawing in ADDENDUM 3 10 minuten Gleu, Drill, core drill (Ø 90), wood drill (Ø 25) Pipes (1 x Ø 90 en 2 x Ø 25), a piece of wood board No parts have been added to the final product This action costs 4 euro for the pipes + 11 euro for the wooden plate. BOTTLEHOLDER2011 4
5 MAKING OF THE RIB-MOLD Take a (preferably left-over) piece of wood ( thickness ± 2cm) and stick the pattern (pdf-file: addendum 4) onto this piece. Use a jig saw to cut out the shapes. TIP: There is a top-side of this mold! Be sure to remember this side (write it on the mold or so). Template in ADDENDUM 4 10 minutes Glue, jig saw There are no standard parts bought No parts have been added This action costs 0 euro. BOTTLEHOLDER2011
6 CURVATURES AT THE BOTTOM Equally heat the lower part of the model with a heat blower. (± 1 minute). Be careful not to heat the material to much or it will pull astray. Now bend the shape around the mold, as demonstrated in the picture. The material has to be pulled very tight around the mold. Be sure that there are no gaps between the mold and the material and that the material rests on the wooden board. Place a board (thickness 1 cm) between the handles and hold everything very tight for a minute There is no technical plan of this part. 4 minutes Heat blower, curvature mold, clamp, board (thickness: 1 cm) There are no standard parts bought No parts have been added This action costs 0 euro. BOTTLEHOLDER2011
7 TOP CURVATURES Take one of the two Ø 25 pipes out of the curvature mold. In turns, heat both narrow ends of the model over a distance of about 1 cm. Then bend these ends around the pipe. BOTTLEHOLDER2011 There is no technical plan of this part. 5 minutes Heat blower, pipe Ø 25 There are no standard parts bought This action costs 0 euro. No parts have been added
8 BOTTLEHOLDER2011 There is no technical plan of this part. 5 minutes There are no standard parts bought This action costs 0 euro. TOP CURVATURES Using a TEMPORARLY piece of string, tie the two legs together. Now heat the rest of the top, bend the two ‘legs’ around the diameter en hold it in place with a clamp. Again, pull the material tight around the pipe and make sure there is no room between the material and the mold. Also make sure the curvature is straight. BE CAREFUL: Don’t heat FOR TOO LONG: This is a very thin piece that can break off very easy. Hot airblower, pipe Ø 25, Clamp No parts have been added
9 BOTTLEHOLDER2011 TOP CURVATURES Once both ends are fully curved, slide the heat shrink over the narrow curved ‘legs’ and tie them together using a piece of nylon wire. There is no technical plan of this part. 5 minutes Nylon Wire, Heat shrink (Ø 6 mm) Two parts have been added: the nylon wire and heat shrink This action costs 2 euro. Nylon Wire, Heat shrink (Ø 6 mm)
10 BOTTLEHOLDER2011 FINISHING THE TOP CURVATURE Slide the heat sink back so that it is equal divided over both legs. Heat the heat shrink for about 2 to 3 seconds with a lighter or the heat blower. You will see that it shrinks around the neck. Let the model dry for a while. BE CAREFUL: Don’t heat FOR TOO LONG: This is a very thin piece that can break off very easy. DON’T touch as long as it’s not cooled down, because this part is still flexible, and you could possibly destroy the curves, created earlier on. There is no technical plan of this part. 1 minute Heat blower This action costs 0 euro. There are no standard parts bought No parts have been added
11 BOTTLEHOLDER2011 CURVATURES OF THE RIBS Heat the rib with a heat blower. Place the rib onto the mold and hold this position for about a minute. Once the material has cooled down, it takes over the shape of the mold. Repeat this with the other rib. Check before you start if you are using the correct side of the mold and the correct sides of the rib you want to curve. There is no technical plan of this part. 5 minutes Heat blower, rib-mold There are no standard parts bought No parts have been added This action costs 0 euro.
12 BOTTLEHOLDER2011 SUPPORT CURVATURE Heat the right part of the small piece (number 10) with the heat blower as described in previous steps. Bend only this part of the piece around the Ø 25 pipe hold this position for a while. Once cooled down, heat the other (not bended) part of piece 10. Assemble it TEMPORARLY to make sure that it touches the ground while assembled (as shown in the picture). Once the material has cooled down, it will keep this curvy shape and the product is able to stand on its own. There is no technical plan of this part. 5 minutes There are no standard parts bought No parts have been added This action costs 0 euro. Heat blower, pipe Ø 25
ASSEMBLY Once you have finished all previous steps, you can start putting al the pieces together. You can see which part goes where in the exploded-view-picture. We advise you to respect the numbering , so that every piece is properly assembled. Use hard PVC-glue to attach al pieces together. TIP: If you work with used polypropylene, it is useful to put al parts in bleach before you assembly them. This will result in whiter and cleaner parts and no more stains, caused by the manufacturing (laser cutting). BOTTLEHOLDER2011 30 minutes Hard PVC-glue Hard PVC-glue No parts have been added This action costs 5 euro. There is no technical plan of this part.