Costing and Production Challenges,
For the sundial's pattern making, its size (40x40x5cm) and its intricate details were significantly expensive with available methods.
Especially for a student with a minimal budget.
SLS 3D-printing the pattern would be 8000 Euros
5-axis CNC machining a metal/wooden block, 1000 Euros
Plus, if I had decided to rather machine a mold directly, available tooling could not produce the sharp edges of the brutalist design.
Therefore, I decided to utilize several manufacturing processes for a modular design to cut down on costs.
Poplar Wood, 8 Euros
Laser-Cut 2mm Acrylic, 30 Euros
SLS 3D Printing markers, 35 Euros
VMC Milling 2mm depth, 15 Euros
Total Cost for Pattern, 88 Euros
11x Cost-Reduction
Mold Making,
For the sundial's mold, I had to take a similar modular approach to minimize costs.
The most efficient approach would have been to use silicone for the whole mold, but I would require 10kg of it, and cost 250 Euros.
On the other hand, by using a combination of plaster and silicone for the base and details respectively, I would only require 1.5kg of silicone, costing me just 40 Euros.
RTV Silicone, 40 Euros
Plaster, 10 Euros
Total Cost for Mold, 50 Euros
5x Cost-Reduction