TITLE:
YEAR:
COLLECTION:
MATERIAL:
SIZE:
MANUFACTURER:
COMPANY:
SHOWN:
Foam Seats
2020
Heavy Duty 2020
PU foam, PU coating
SIZE: H:78cm D:120cm W:86cm
Gaetano Di Napoli, Cooloo Coatings
Gaetano Di Napoli, Cooloo Coatings
Copenhagen 2021, Post Service
Duration: 11.12.19
Product: The product range of Gaetano Di Napoli ranges from various mattrass products over sound insulation to customized foam goods. For their production, they use oscillating band saws to cut the big foam blocks vertically and horizontally.
By-product: Like any other cast semi-finished products, the polyurethane foam ingots have a casting crust. During the production of foam products, Di Napoli is removing and discarding this outer layer. Imperfect and damaged products are sorted out as well. Gathered and compressed to a 400kg package, the offcuts are sold to a recycling company that is producing composite foam out of it.
Inspiration: A main inspiration was composite foam, the already recycled material in itself. I was interested in the step before the production of this product. After visiting Di Napoli for the first time, I was impressed by the size of the discarded offcuts. In the composite foam, one can only see the shredded state of it. The potential of the actual dimension is lost in the recycling process.
Organisation: Getting a foot into the doors of Di Napoli took a few tries. Me as an unknown student, wanting to work in their very busy and tight facilities led to rejection at first. After I came up with a simple idea that would be realizable within a few hours, Di Napoli was very supportive.
Potentials: Foam has the property to cushion and provide comfort. The main potential of Di Napoli’s by-products was the size of the discarded foam skins. Also, they had different densities available. The expertise of the workshop and workers held the potential of cutting and gluing the material into any thinkable shape.
Challenges: Since Di Napoli was sceptical at first, I did not want to take a lot of their time. Hence, I was aware of my limited time of use of their machines to not disturb their daily production.
Goals: The plan I wanted to realise was based on an efficient use of the size of the offcut materials. By gluing the skins together, a block is (re-)created. With a single cut through the block using a band saw, two couches should be generated without producing any further offcut material. The resulting pieces should then get coated at CooLoo.
Production: The layering was planned from hard foam for the first substructure to soft foam for both seating surfaces and backrests back to hard foam for the second upside-down substructure. The first step of the production was to collect appropriate material for this. Before gluing the material into a block, loose material needed to be removed. The block was trimmed and halved. I drew lines on the side of the blocks and a craftsperson cut along it with the help of a band saw. The results were four comfortable foam chairs without offcuts.
Reflexion: Unfortunately, my project ended up disturbing the daily production of Di Napoli. Due to a misunderstanding, the cutting process changed and took a lot longer then I planned. Out of time pressure, I proposed the simple solution of dividing the block into halves and cutting them by hand according to a line, which I drew on the side of the block before. The trimming of the glued block was not intended and happened according to the rules of one worker. The preconception and self-expectation of the operating craftsmen influenced the design. After all, I am very grateful for the material and helping hands that were given to me.
Duration: 16.12.19 - 17.12.19
09.01.20 - 10.01.20
Product: CooLoo is a Dutch company that is focussing on the development and production of coatings for furniture design. With their polyurethane based technique, CooLoo can seamlessly coat any material in any shape and size. Their sustainable coatings consist of by- products of the leather and cork industry.
By-product: The leather industry produces a powder- like by-product as a result from sanding. CooLoo has developed a technique that allows them to spray this leather powder onto a polyurethane basecoat. The result is a seamless recycled leather coating. The same technique enables them to spray recycled cork flakes and other coatings.
Inspiration: The wish to upholster and protect a foam object in an innovative and sustainable way was just a logic step.
Organisation: Five minutes after I proposed the same idea to CooLoo via mail, they replied with enthusiasm and a few days later, I was standing in their workshop discussing the collaboration and upcoming production processes.
Potentials: The potential of the coating technique of CooLoo was to reinforce the foam surface with a flexible cover. Furthermore, I saw the chance to blend materials, surfaces and colours due to the spraying technique.
Challenges: -
Goals: The plan I wanted to realise was based on an efficient use of the size of the offcut materials. By gluing the skins together, a block is (re-)created. With a single cut through the block using a band saw, two couches should be generated without producing any further offcut material. The resulting pieces should then get coated at CooLoo.
Production: In a next step, the chairs are coated in the workshops of CooLoo. I decided to coat one of the chairs in a clear coat to show the pastel colours of the original foam. The other chairs are coated in a gradient manner to emphasis the spraying process.
Reflexion: In the Netherlands at CooLoo’s workshop, it felt like I was in a very likeminded environment. All the imperfect and process driven aesthetics I wanted to deliver were understood and supported.
Prospect: Since CooLoo asked for marketing the proposed design further, there is the need of a further production plan. I realised, it would be a lot easier to source the foam by-product and the production from a foam supplier that stands in contact with CooLoo already. Also, I would like to explore CooLoo’s by-product further. When they are spraying their coats onto objects in the coating room, a lot of dust is generated that settles on the walls and floor. It is creating a unique passively produced coat with a lot of depth. As this layer grows with time, one can put an object in the chamber and harvest it when it is fully covered.
TITLE:
YEAR:
COLLECTION:
MATERIAL:
SIZE:
MANUFACTURER:
COMPANY:
SHOWN:
Foam Seats
2020
Heavy Duty 2020
PU foam, PU coating
SIZE: H:78cm D:120cm W:86cm
Gaetano Di Napoli, Cooloo Coatings
Gaetano Di Napoli, Cooloo Coatings
Copenhagen 2021, Post Service
Duration: 11.12.19
Product: The product range of Gaetano Di Napoli ranges from various mattrass products over sound insulation to customized foam goods. For their production, they use oscillating band saws to cut the big foam blocks vertically and horizontally.
By-product: Like any other cast semi-finished products, the polyurethane foam ingots have a casting crust. During the production of foam products, Di Napoli is removing and discarding this outer layer. Imperfect and damaged products are sorted out as well. Gathered and compressed to a 400kg package, the offcuts are sold to a recycling company that is producing composite foam out of it.
Inspiration: A main inspiration was composite foam, the already recycled material in itself. I was interested in the step before the production of this product. After visiting Di Napoli for the first time, I was impressed by the size of the discarded offcuts. In the composite foam, one can only see the shredded state of it. The potential of the actual dimension is lost in the recycling process.
Organisation: Getting a foot into the doors of Di Napoli took a few tries. Me as an unknown student, wanting to work in their very busy and tight facilities led to rejection at first. After I came up with a simple idea that would be realizable within a few hours, Di Napoli was very supportive.
Potentials: Foam has the property to cushion and provide comfort. The main potential of Di Napoli’s by-products was the size of the discarded foam skins. Also, they had different densities available. The expertise of the workshop and workers held the potential of cutting and gluing the material into any thinkable shape.
Challenges: Since Di Napoli was sceptical at first, I did not want to take a lot of their time. Hence, I was aware of my limited time of use of their machines to not disturb their daily production.
Goals: The plan I wanted to realise was based on an efficient use of the size of the offcut materials. By gluing the skins together, a block is (re-)created. With a single cut through the block using a band saw, two couches should be generated without producing any further offcut material. The resulting pieces should then get coated at CooLoo.
Production: The layering was planned from hard foam for the first substructure to soft foam for both seating surfaces and backrests back to hard foam for the second upside-down substructure. The first step of the production was to collect appropriate material for this. Before gluing the material into a block, loose material needed to be removed. The block was trimmed and halved. I drew lines on the side of the blocks and a craftsperson cut along it with the help of a band saw. The results were four comfortable foam chairs without offcuts.
Reflexion: Unfortunately, my project ended up disturbing the daily production of Di Napoli. Due to a misunderstanding, the cutting process changed and took a lot longer then I planned. Out of time pressure, I proposed the simple solution of dividing the block into halves and cutting them by hand according to a line, which I drew on the side of the block before. The trimming of the glued block was not intended and happened according to the rules of one worker. The preconception and self-expectation of the operating craftsmen influenced the design. After all, I am very grateful for the material and helping hands that were given to me.
Duration: 16.12.19 - 17.12.19
09.01.20 - 10.01.20
Product: CooLoo is a Dutch company that is focussing on the development and production of coatings for furniture design. With their polyurethane based technique, CooLoo can seamlessly coat any material in any shape and size. Their sustainable coatings consist of by- products of the leather and cork industry.
By-product: The leather industry produces a powder- like by-product as a result from sanding. CooLoo has developed a technique that allows them to spray this leather powder onto a polyurethane basecoat. The result is a seamless recycled leather coating. The same technique enables them to spray recycled cork flakes and other coatings.
Inspiration: The wish to upholster and protect a foam object in an innovative and sustainable way was just a logic step.
Organisation: Five minutes after I proposed the same idea to CooLoo via mail, they replied with enthusiasm and a few days later, I was standing in their workshop discussing the collaboration and upcoming production processes.
Potentials: The potential of the coating technique of CooLoo was to reinforce the foam surface with a flexible cover. Furthermore, I saw the chance to blend materials, surfaces and colours due to the spraying technique.
Challenges: -
Goals: The plan I wanted to realise was based on an efficient use of the size of the offcut materials. By gluing the skins together, a block is (re-)created. With a single cut through the block using a band saw, two couches should be generated without producing any further offcut material. The resulting pieces should then get coated at CooLoo.
Production: In a next step, the chairs are coated in the workshops of CooLoo. I decided to coat one of the chairs in a clear coat to show the pastel colours of the original foam. The other chairs are coated in a gradient manner to emphasis the spraying process.
Reflexion: In the Netherlands at CooLoo’s workshop, it felt like I was in a very likeminded environment. All the imperfect and process driven aesthetics I wanted to deliver were understood and supported.
Prospect: Since CooLoo asked for marketing the proposed design further, there is the need of a further production plan. I realised, it would be a lot easier to source the foam by-product and the production from a foam supplier that stands in contact with CooLoo already. Also, I would like to explore CooLoo’s by-product further. When they are spraying their coats onto objects in the coating room, a lot of dust is generated that settles on the walls and floor. It is creating a unique passively produced coat with a lot of depth. As this layer grows with time, one can put an object in the chamber and harvest it when it is fully covered.