Custom Glass Castings from Digital Designs

This post is a follow up to a previous one about techniques that I have been exploring to transfer digital designs into cast glass objects. This began last year at a fellowship at  Wheaton Arts’ Creative Glass Center of America and was expanded upon this year while teaching at Pilchuck Glass School and in a workshop at Detroit’s College of Creative Studies. In particular, I have  focused on one particular technique; using a low cost desktop CNC machine to carve reusable graphite molds for glass casting multiples. There’s a few design limitations to this approach, but it is an amazingly cost effective approach to creating small to medium scale runs of custom designed glass tiles. The molds hold up for hundreds of castings, and possibly even more, so this is an exciting way of creating custom glass design objects and custom tiles for architectural applications. This will be a big focus for much of my work in 2017.

With a clean and simple design, these new geometric tiles channel the 1980’s era video game Qbert, Islamic mosaics, and leverage the material’s clarity and sparkle. I love the simplicity and the illusory way we see through the smooth top surface to see the relief texture on the backside. I am thinking this will become a set of tabletop design objects, with 6″,9″ and 11″ sizes that interlock. However, I am almost more excited to think of them as architectural tile. How cool would it be to have a wall made of these, or have them as accents embedded in concrete?

Below you will see some of this new carved graphite mold work, as well as some student work from teaching at Pilchuck this summer.  Design constraints of this method center around the fact that this process does not support forms with undercuts. Likewise, the machine can only mill material up to ~2.5″ thick and can only do straight plunge cuts as long as the longest router bit you can find. For most 1/8″ bits this means you cannot do any straight cuts more than 1.5″ deep. However, because graphite is a lubricant and it pretty impervious to heat, once the moisture leaves the material after the first few casts, these molds can be used over and over again, with beautiful results. For any schools or glass studios who are looking to create such a setup, I have created a bill of materials for creating such a setup, totalling under $2500. (BTW, I am available to teach workshops! )

The top of the casting is flat, perfectly magnifying the relief texture of the underside.

img_6550

CNC milling the graphite mold

Completed rough pass on CNC, ready for finishing pass

Ladling molten glass into the finished mold

img_4978

The tile on the left is upside down, showing the relief on the backside. The relief side is as nice as the front and they would make a beautiful glass brick wall.

I’ll end with some images from the TaDDDaa!!! class at The Pilchuck Glass School this summer. It was a three week deep dive into 3D modeling, scanning, printing and CNC carving. Here’s some of the class’ work with graphite for glassmaking:

img_6421

This was my first test with this technique at Wheaton Arts and the process used by students for the class at Pilchuck. Here we see rough and smooth CNC carving of the graphite mold, hot glass in the mold, and final product at room temperature.

img_0365

The TaDDDaa!!! class at Pilchuck was a three week deep dive into 3D modeling, scanning, printing and CNC carving.

img_9621

My TA Christian with Phirak and Rebecca, who will be teaching a 3D printing clay class at Pilchuck next summer

img_3624

Rebecca’s mold based on a victorian pattern

img_9784

Jameszie made a Ouija planchette

img_3645

Brent supervising his first carve

img_9746

John, Lee, Phirak and Nikki trying out their molds

img_9827-2

My student John was a master mold maker so he undertook making a two part blow mold and spent quite some time finishing the graphite to a polish

img_9829-2

Blowing glass into the mold

img_9847

Michael’s two part blow mold

img_9749-2

A pile of hot casting molds cooling down at the end of the class casting session

img_0375

A fishscale tile design I was playing with

CNC Carving Glitch Art

Greetings from the woods of Stanwood Washington where I am teaching in the remote paradise known as the Pilchuck Glass School. Session 2’s theme is Play and our class has been playing with methods of creating glass castings from digitally generated sculptures. 

As part of the class we are CNC carving graphite molds so I brought a bunch of graphite that I bought on eBay. I had previously carved blocks that I had bought from this guy with no problems so I was bamboozled when I started to have carving issues with my molds here. I spent the better part of the last two days wrestling with the XCarve, thinking the axis slipping was mechanical. Then I realized the carbide bit was totally shot and realized the problem. The CNC is finally back to carving the other/ softer graphite like it was butter. I finally carved this mold I’ve been trying to make, but only did the rough pass. I think I like the terraced stepping… What do you think!? 

In the meantime, please enjoy my latest work with graphite glitches….







Come Learn 3D Modeling, Scanning, Printing & Glass Casting with me at Pilchuck in June!

There’s only a few weeks until my class TaDDDaa!, which covers a range of digital processes for glass casting at the Pilchuck Glass School in Stanwood Washington and there’s still a couple slots available! Session 2 runs May 30-June 17. The course will combine a 3D modeling, scanning and 3D printing/CNC routing track with a physical track for glass casting with lost PLA kiln casting and hot casting into CNC carved graphite molds.

Apply today and join me in the woods for the time of your life!

digital-glass

This sequence shows the progression of a 3D scan being manipulated digitally, the 3D printed sculpture, and its final incarnation as a cast glass object.

Kahl,Fred-Image-10

This sequence shows a CNC routed mold that can be used for hot glass casting.

TaDDDaa! A Class in Digital Processes for Glass Casting at Pilchuck Glass School

Kahl,Fred-Image-10I’m please to announce that I will be teaching a class at the Pilchuck Glass School in June of 2016. The class will cover a lot of the digital to physical techniques that I have been working with over the last few years, particularly this past year with my fellowship at Wheaton Arts Creative GLass Center of America (Stay tuned, I will be publishing my finding soon).

The intensive 3 week class will take place in June of 2016. Pilchuck’s session 2 this year has a theme of Play, and we certainly will be playing with ways of bringing the 21st century to glassmaking’s 19th century traditions.

TADDDAA! 
May 31- June 17
3-D Modeling & Printing, Lost PLA, CNC, Kilncasting, Hot Casting

Digital sculpting and 3-D printing tools allow artists to visualize prototypes, manipulate scale, and replicate with precision. This course will introduce an assortment of tools including Zbrush (an organic sculpting software), 3-D printers, and 3-D scanning methods of photogrammetry and structured light. Students will learn to scan, manipulate, and print objects and ultimately kilncast and hot cast them in glass. This class is for glass artists who wish to explore digital fabrication and 3-D artists who wish to explore glass.
http://pilchuck.com/summer_program/courses/session2.aspx

The class will cover:

  • 3D Modeling with Zbrush
  • 3D Scanning with structured light and photogrammetry
  • 3D Printing
  • Moldmaking
  • Glass kiln casting with lost PLA
  • CNC milling of graphite molds for hot glass casting

It’s going to be an awesome class and I’m looking for two teaching assistants. Applications for TA’s are due February 3. I would like to find one TA who is well versed in 3D modeling and 3D printing (its a + is you own or have built a 3D Printer), and another who is familiar with glass kiln casting. Please help spread the word!

Greetings From Pilchuck!

I’ve just completed two weeks as a visiing artist at the Pilchuck Glass School in Stanwood, Washington. It’s been 21 years since I have been here and I’m happy to say that Artistic Director Tina Aufiero is doing a great job of pushing the school forward into the 21st century while maintaining the atmosphere of collaboration, comraderie, experimentation and creativity. 

I was brought out to get the new 3D printing studio space set up in preparation for classes this year, and to plan my 2016 class on using digital processes and 3DP for creation of glass objects. It was an awesome experience and much needed moment of reflection. I was able to generate some work in preparation for the upcoming Wheaton Arts fellowship and even got to dabble in glassmaking while making new friends and reconnecting with old ones.  

Here’s some images: 

The iconic Pilchuck Hot Shop

    

Hank Adams’ Trojan Horse has grown a wonderful patina over the years

        

as Always, the hot shop was bustling with action- pulling glass tubes for neon here

  

Sunset over Puget Sound as seen from the lodge

  

“Creation” 3D Print- a maquette for my Wheaton Project? Picture this 12′ tall! Made on the new Printrbot Bot Farm.

  

Gaffer Dan Friday helped me make a piece, starting with this gold Ruby glass heart

  

Hot glass is a seductive material

  

This 3D printed scan if my hand was inspiration for this hot glass sculpted piece

  

Hand with heart being reheated in the glory hole.

  

The Heart in the hand

  

Il Cavallo- the glass Horse: I see the glass horse as the ultimate test of glassblowing prowess. what the paper crane is to Origami, il cavallo is to glass. if you can work hot enough to make the horse without reheating, you are a skilled glassworker. Watch my YouTube olaylist of Glass Horse making here: https://www.youtube.com/playlist?list=PLZroWUSkyKpFH_TNnoYe2JcpZcVCiRBcC

  

Pilchuck Totem Pole made by Preston Singletary and other pacific Northwest natives with cast glass inclusions

        

My last night ended with a gallery show. of 3D printed and glass work

 

Creation Maquettes

  

3D Portraits

  

Portrait of Artist in Residence Joel Otterson

      

Glass hand holding Heart

  

Dan Friday Portrait

  

Il Cavallo

  

Goodbye Pilchuck! im excited to teach session 2 , 2016!

  

Bay Area Maker Faire Talk: Fredini’s History of Technology as Entertainment

Its been a whirlwind ever since I went out to San Francisco for Maker Faire. I meant to post a recap of some of my favorite highlights of the weekend, but have been swamped with Scan-A-Rama and getting ready for this year’s fellowship at Wheaton Arts. This week I’m doing a quick visiting artist stint at the Pilchuck Glass School to get a 3D printing studio up and running. I’ll be teaching a course there next summer about methods of creating 3D printed models for glass casting… more on that later (but I’ll be looking for artistic teaching assistants with expertise in 3D printer building, 3D modeling and glass casting, so give me a shout if you’re interested!).

In the meantime, Maker Faire posted my talk on YouTube. Overall, I’m happy with it. I confess I was called out by a fan for screwing up the Arthur C. Clarke quote, which should read “Any sufficiently advanced technology is indistinguishable from magic.“. Anyway, here’s the talk, and if you get a chance its just one of a playlist of a lot of great pieces, so check them all out!