01
Material Experimentation
We are experimenting with various bioplastic recipes such as gelatin, agar, soap foams, algae foams, and cornstarch plastics to decide which material works as the best replacement for the classic foam darts.
02
Making our molds
We CAD modeled and 3D printed molds for our darts. We wanted to experiment with various molds for the base when pouring the foam substance in order to create the best dart structure.
03
Petroleum Foam Trial Mold
We attempted to create our dart body with petroleum foam in our 3D-printed molds. We sought to practice creating foams in a similar fashion to the way the algae foams are made as well as test the capabilities of our mold designs. Additionally, we wanted to find out if silicone spray is beneficial in the removal of molded contents.
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We used a kit with prepared chemicals as well as food coloring to create the foam in a separate container and transferred the mixture into molds sprayed with silicone. The separation of the individual mold pieces was also difficult, even with the application of the silicone before the mixture was added. We reason that the dye could have influenced the chemical reaction, resulting in the crumbly material we are observing from this attempt.
04
Mold Redesign
We analyzed areas that our molds could be improved in order to make the experimentation process easier. The molds for the foam body were CAD modeled to be cylindrical and make all materials inside the molds more easily removable. The lid of the tip molds have been altered to allow for more material space at the end of the tip.
05
Soap Foams
The Soap Foams have been successful! The soap foam requires heavy aeration which must be done by a mixing motion similar to whipping of egg whites for baking purposes. The resulting material is soft and compressible, but has some varied texture once settled. The material formed at the bottom of the container was akin to gelatin, but this aspect may be of benefit to our design if we decide to use gelatin as our tip material.
06
Gelatin Tips
The gelatin held the form effectively and proved to be a good potential material for the dart tips. It comes with the added bonus that the material is malleable while simultaneously maintaining its form. However, it may be susceptible to tearing from repeated stretching and pressing, particularly on the top of the tip depending on how thin the substance is made.
EXPERIMENTAL MATERIALS
SOLEIC™ by Algenesis
The foam uses algae oil to create polyurethane monomers; however, unlike polyurethane that uses petroleum monomers, algae foam can biodegrade in the soil in about twelve weeks.
GELATIN BIOPLASTIC
A flexible animal based bioplastic that simulates a rubber like substance. Ingredients: Glycerine, Water, Gelatin.
AGAR
A plant based bioplastic that can simulate soft and hard plastics depending on the manufacturing process. Ingredients: Glycerine, Water, Agar
GELATIN
SOAP FOAM
An animal based bio foam that uses a liquid dish soap and gelatin combination to naturally foam bubbles in the substance.
Ingredients: Glycerine, Water, Gelatin, Dish Soap