BioBrush explores the potential of using agar-based bioplastics to create over molded products. In this project, I focused on the research, material experimentation, and mold making processes.
TESTING HYPOTHESIS
MATERIAL EXPLORATION
INITIAL BIOBRUSH DESIGN
My goal was to create a bioplastic product that exhibits both rigid and flexible qualities through the process of over molding. I designed an agar-based toothbrush with a hard skeleton and a soft handle, with a snap-in bristle head for easy disposal. BioBrush provides a compostable alternative to single-use over molded toothbrushes.
MOLD MAKING
In order to create an over molded product, I had to design a mold that would allow me to cast the hard skeleton material, hold the object in place, and replace pieces of the mold to then cast the soft handle material on top of the skeleton.
CASTING PROCESS
Through several iterations, I was able to refine the the transition from cooking to pouring, the amount of time between casts, and the amount of time the material was kept in the first and second shot molds.
DESIGN ITERATIONS
MOLD MODIFICATIONS
In order to rapidly and iteratively change the form of the toothbrush, I would make modifications to the 3D printed mold. One example is changing the toothbrush head form a snap-in solution to stapled bristles due to choking hazard concerns. To increase the thickness of the toothbrush neck and add material to the toothbrush head, I used the Dremel to remove material from the mold, thus increasing the size of the casted form.
FUTURE CONSIDERATIONS
BIOBRUSH