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SKETCHING PROCESS
PROCESS
Follow our development process.
Look at our first sketches, remarks, laser cutting, heat pressing, laminating and ultra sonic welding.
CREATING OUR OWN LAMINATE
With the techniques of laser-cutting and heat-pressing we created our own air-proof fabric laminate. We tried several different air cushion constructions. We focussed on the different behavior of glued areas in comparison to voluminous air filled areas.
One laminated fabric consists of one layer of fabric + one layer of glue + one layer of fabric. This creates an air-proof 3-layers laminate. The glue foil needs to be lasercut first and will be heat pressed between two pieces of laminate afterwards.
Every structure leads to a different result.
We have alternated the sizes of the areas filled with air in comparison to the other areas without. This effects the volume and shape of the piece.
One of the biggest learnings in the development process, is the importance of the bridges in between the air cushions. If the bridges are too small, they will burst under the pressure, or not every cushion will be filled with air properly.
developing a structure
swatches
honeycomb construction
honeycomb lasercut
weaving
honeycomb construction
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Click through our Gallery and look at our different swatches and their development.
We varied laminating dead-stock-materials: elastic sportswear knits, jerseys, woven polyesters, thin and thick fabrics. The swatches are air-proof and diverse in form and fabric. The sample piece shown in the video on the left is even elastic.
ULTRA SONIC WELDING
Ultra sonic welding isn´t too different from sewing. Instead of stitching materials together the materials are welded together by high-frequency ultrasonic vibrations that are locally applied to the materials being held together under pressure to create a solid-state weld. In other words: the materials are connected through heat that is created through friction that is caused by the vibrations of the lower wheel, while the upper wheel only rotates to process the material.
filling the cushions with air
This one held the air for more than one day even without propper closure
checking the parameters
inside view and structure
filling up air, looking for flaws
original welding seam
inside view and structure
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