.Zinc coaster concept development

I felt the zinc coaster had more areas of expansion in terms of product development. Upon speaking to the tutors, I should apply multiple uses to the zinc coaster as its a bit "2-d" in form.

one of the ideas was to possibly follow through with the flower design and use the petals as a cupholder by bending them upright against the cup. also i could make multiples of the coaster to combine them together creating placemats for bowls.

.Searching for the material
class mate gave me a "zinc" sample which was a soft, extremey flexible metal strip
i went to bunnings but could only find zinc steel, which is too hard to work with.
called up a metal manufacturig company in rozelle and they told me they had pure soft metal zinc, however when i got there the sample they gave me was ideal to work with my idea but not for making the presentation model. it came in sheet thickness of 1mm and in rolls. and the strip i was holding turned out to be poisonous lead! eeeek!


.Searching for manufacturing process
whilst searching around i found interesting techniques:
1. electroforming
metal part is fabricated through electrodepositing of metal (in electrolyte solution plating bath) onto a mandrel/base which is removed after metal skin is built up on the surface.

2. Chemical-etch stenciling
Stencil is created on photographic paper which is then adhered on to a clean surface of the sheet metal. Acid is used to dissolve unwanted sections.

Initially I opted for the electroforming process but this would be more suitable for 3d objects. However I called up a Chemical-etching company in QLD and was advised that waterjet cutting would be more suitable for sheet material of 1mm thickness and easier and more economic to mass produce.
3. Waterjet Cutting
water of high velocity and pressure combined with an abrasive substance (eg. aluminium oxide) is used to slice metal. An autocad drawing/dwg file is required to control cutting of the design.


.Final Design


and oh i was told to look in zarf cups which decorative cupholders from turkey:



Unrelated side note: RIP my watch, lost somewhere (possibly in my room) and unable to find :( a dear friend bought it for me from moma store in NY. i am quite saddened and hopeful for its reappearance in near future.