Inflating metal 10-11, 76-7

inflating wood 14-15, 184-6

injection blow molding 6, 12-13, 127, 129-31

injection molding 6, 8, 14-15, 23, 94, 120, 137, 169, 176, 177, 196-211

pre-form (bottle) 76-7, 129-31

injection stretch molding 127, 129

inkjet printers/printing 7, 8, 14-15, 240-1, 242, 244, 262

insert molding 206-8

investment casting 14-15, 224-7

Ion-mask™ 269

iPod Mini, Apple 279

iPod Shuffle, Apple 279

i-SD system 268

Ito, Setsu and Shinobu 52

Jackson, Kathryn 257

Jack-stand 61

jars, glass 124-5

jiggering 10-11, 29-31

jollying 10-11, 29, 30, 32

Jordan, Malcolm 7, 84, 184-5

Jouin, Patrick 248

Kami no Kousakujo (Japan) 46

Karkov, Simon 40

kerf 34

Keronite^® 270

Khoshnevis, Dr. Behrokh 244

Kikkoman bottle 120

Kikkoman Corporation (Japan) 120

King Dick Tools (UK) 187

knife, “Kyotop” range 170

knurling 18

Kolte, Olof 228

Komplot 83

KX Designers 265

Kyocera (Japan) 170

Kyotop range, knife 170

Laleggera range, chair 181

lamp, Air Switch flask 116-7

lampshades

Leonardo 112

metalized copper finish 262

Norm 69 40

Wednesday Light 263

lampworking glass tube 12-13, 118-9

Lapalma (Italy) 80

laptop computers

E-Go 214

VAIO 262

laser cutting 10-11, 23, 25, 30, 46-7

laser engraving 264

laser-beam machining 46-7

lathe operations 18, 19, 20, 26, 118, 119

lemon juicer 231

Leonardo lampshade 112

Levy, Ark 246

liquid-repellent coatings 269

London Underground 281

Loo range, bath 234

lost-wax casting see investment casting

Louis-Jensen, Toby 70

Ludvik, Gudmunder 80

machining 9, 10-11, 18-20

Macor 19

Magis (Italy) 130, 179, 201

Maglica, Anthony 18

Maglite Instruments Inc. (USA) 18

Maglite^® torch, Mini 18, 279

magnetic fields 54-5

Manzini, Ezio 260

Mari, Enzo 178, 179

Marloes ten Bhömer (UK) 137

Matchbox (UK) 219

Matchbox “Lotus Europa” 219

Materialise (Netherlands) 246

Mathmos Design Studio (UK) 116

Matsui, Yoshiyuki 170

Mcor Technologies Ltd (UK) 242, 243

medical implants (hip-bone plate) 24

melamine 86, 87, 175

menu, edible 240

metal injection molding (MIM) 14-15, 216-8

Metal Injection Mouldings Ltd (UK) 216

metals

backward impact extrusion 146-8

case hardening 272

chemical milling 38-9

centrifugal casting 12-13, 161-3

ceramic coating 270

CO2 silicate casting 228

cold isostatic pressing (CIP) 172-3

cutting 10-11, 18, 59-60

deburring 275

decorative finishes 263, 264

electroforming 164-5

electromagnetic forming 54-5

electropolishing 265

forging 187-9

free internal pressure-formed steel (“FIDU”) 10-11, 73-5

galvanizing 275

high-pressure die-casting 219-21

hydroforming 12-13, 143-5

incremental sheet-metal forming 14-15, 57, 257-9

inflating 76-7

investment casting 14-15, 224-7

laser cutting 47

machining 9, 18, 19

metal injection molding (MIM) 216-8

milling 20

oxyacetylene cutting 48-9

phosphate coatings 271

pickling 277

plasma-arc cutting 10-11, 25, 33-5

powder coating 270

powder forging 14-15, 190-1

pre-crimp weaving 12-13, 108-11

roll forming 104-5

rotary swaging 12-13, 106-7

sand casting 228-30

sheet-metal forming 50-1

shot peening 274

sintering 168, 190, 217, 218, 252

spinning 10-11, 56-8

superforming, aluminum 10-11, 70-2

water-jet cutting 42-3

wire EDM (electrical discharge machining) 44-5

microcellular foam 203, 204

micro-molding 250-1

Miele 260, 263

Mikroman business card 38

milling 19, 20

Mimotec (Switzerland) 250

Mini Maglite^® torch 18, 279

Mining and Chemical Products Ltd (UK) 252-3, 254

mirrors 276

MN01 bike 70

Morrison, Jasper 201

mortar 27, 28

Moto Restaurant (USA) 240

molding, paper pulp 12-13, 78-9, 149-51

MuCell^® injection molding 14-15, 203-5

multicomponent molding 206-11

multishot injection molding 209-11

Mycalex 19

Mykroy 19

nano-scale components 25, 251

NASA 266

Naunheim, Karsten 143

Neville & Sons (UK) 86, 87

Newby, Stephen 72, 76

Newson, Marc 70, 72, 234

Nextel 266

nibbling 59

Nichetto, Luca 262

non-chip-forming processes 46-7, 59

nonstick coating 278

Norm 69

lampshade 40

Normann Copenhagen (Denmark) 40

open-die forging 187, 189

over-mold decoration 14-15, 213, 214-5, 267

oxyacetylene cutting 10-11, 33, 34, 35, 48-9

oxygen cutting see oxyacetylene cutting Oyster cards 273

P2i 269

packaging

die cutting 41

injection molded 197

sheet material 37

painting, surfaces 260

paper

calendering 90

laser cutting 46

molding 12-13, 78-9, 149-51

recycling 149, 242

paper-based rapid prototyping 242-3

Parupu chair 78

pen, BIC^® Cristal^® ballpoint 196

perforating 59

pestle 26-28

phosphate coating 271

photo-etching

see chemical milling

photo-quality printers 161

pickling 277

pipes 161

Pizza Kobra light 279

plasma-arc spraying 274

plasma electrolytic oxidation (PEO) 270

plasma-arc cutting 10-11, 25, 33-5

plastic bottles 6, 76, 115, 130, 133

plastics 236

autoclave molding 156-7

blow molding 12-13, 76, 115, 127-8

blown film 12-13, 92-3

calendering 90-1

components 64

contact molding 152-3

die cutting 40-1

dip molding 134-6, 280

Exjection^® 94-5

extrusion blow molding 127, 132-3

fiber-reinforced 99-100, 102, 152

filament winding 158-60, 255-6

foam molding 14-15, 178-80

foam molding into plywood shell 14-15, 180-3

gas-assisted injection molding 196, 201-2

i-SD 268

in-mold decoration 212-3, 268

injection molding 120, 127, 129-31, 137, 196-211, 214

insert molding 206-8

molded 203-4

MuCell^® injection molding 203-5

over-mold decoration 214-15

precise-cast prototyping (pcPRO^®) 14-15, 192-3

pultrusion 99-101

roll forming 104-5

rotational molding 137-9

sheet 90, 138

sintering 168

Smart Mandrels™ 255-6

stereolithography (SLA) 246-9

sublimation dye printing 262

thermoforming 64-6

thermoplastics 95, 124, 197, 201-2, 207, 211, 270

thermoset 174, 176, 177, 207

thick-film metalizing 273

transfer molding 176-7

vacuum infusion process (VIP) 154-5, 177

vacuum metalizing 262

vapor metalizing 276

water-jet cutting 42-3

plastic-state forming 194

plate, Wedgwood^® 29

plating, surfaces 260

Plopp stool 73

plug, electrical 174-5

plug-assisted forming 65

plywood 112

bending 10-11, 80-2, 113, 184

deep three-dimensional forming 10-11, 83-5

and foam molding 14-15, 180-3

furniture 21-2, 80-5, 113, 181-3, 185

inflating 184-6

machining 21-2

pressing 10-11, 86-7

veneer cutting 112-13

polar winding 158

polishing 19

Pollock chair 138

Polyactic acid (PLA) 78

Polycast Ltd (UK) 224

polyethylene terephthalate (PET) 41, 128, 129, 130, 131, 133

polytetrafluoroethylene (PTFE) see Teflon^®

Potter & Soar (UK) 108

powder coating 270

powder forging 14-15, 190-1

powder metallurgy 167, 168, 170, 190, 252, 254

precise-cast prototyping (pcPRO^®) 14-15, 192-3

pre-crimp weaving 12-13, 108-11

press and blow molding 124-6

press forging 188, 191

press forming 59

pressing, plywood 10-11, 86-7

pressing glass 12-13, 231-3

pressure-assisted drain casting 234

pressure-assisted slip casting 14-15, 141, 234-5

pressure-bag forming 152, 153

pressure forming 65

pressure sintering 168

pressureless sintering 168, 169

pressuring glass 14-1

Prince chair 42

printers 7, 8, 14-15, 240-1, 242, 244, 262

protective coatings 273

pull tab, beverage can 59

pulp paper 10-11, 78-9, 112, 149-51

Pulshaping™ 12-13, 102-3

pultrusion 12-13, 99-101

Pultrusion Dynamics, Inc. (USA) 102

punching 59, 60, 105

PVC sheet 90, 91

radio frequency identification (RFID) tags 273

ram method, wire EDM 44

rapid prototyping 7, 14-15, 17, 23, 79, 169, 193, 246, 254, 273

paper-based 242-3

reaction injection molding (RIM) 14-15, 153, 199-200, 211

reaming 20

recycling 19, 23

aluminum 60, 72

glass 53, 117, 233

ink cartridges 241

metals 41, 51, 63

over-molded products 267

paper 149, 242, 243

plastics 41, 65, 100, 173, 280

plywood 81

see also under individual processes

Reholz^® (Germany) 83, 84, 85

reinforced reaction injection molding (RIM) 199

reinforcement fibers 99, 100, 101, 102, 152, 154, 156, 158, 175, 176, 199

Revelation World Cup

adjustable bike fork 2011 270

Rexam (UK) 59

robot transfer, insert molding 207

RockShox 270

roll forming 12-13, 104-5

rotary cutting 112, 113

rotary swaging 12-13, 106-7

rotary transfer, insert molding 206

rotational casting see rotational molding

rotational molding 12-13, 137-9

roto molding

see rotational molding

rough pulp molding 149

Royal Doulton (UK) 140, 236

Rune, Claesson Koivisto 78

Saloga, André 143

sample components 192

sand casting 14-15, 228-30

sandblasting 267, 274

Santa & Cole (Spain) 112

screen printing 264, 273, 277

screw threads 18, 20, 147

screwdriver, Stanley DynaGrip Pro 206

Seggiolina POP chair 178, 179

selective laser sintering (SLA) 14-15, 169, 247, 252-4

selective laser melting (SLM) 252-3

self-healing coating 269

semicentrifugal casting 161, 162

Serra, Richard 105

shape-memory technology 255

shearing 59

sheet glass 52-3

sheet material, products made from 37-87

sheet-metal forming 10-11, 50-1

shell casting 228, 229

shoes, rotational molded 137

shot peening 274

shrink-wrapping 280

Sigg drinks bottle 146, 148

sinter forging

see powder forging

sintering 14-15, 168-9, 170, 190, 217, 218, 252

slicing 112

slip casting 12-13, 27, 30, 137, 140-2, 235

slumping glass 10-11, 52-3

Small Precision Tools (USA) 222, 223

Smart Mandrels™ 14-15, 239, 255-6

Sodra Pulp Labs (Sweden) 78, 79

solid-state forming processes 167-93

Sony 262

Southern California, University of 244

South Carolina, Medical University of 8, 241

spanner 187

spark eroding see wire EDM (electrical discharge machining)

spark machining see wire EDM (electrical discharge machining)

spark plug 172

spark sintering 168

Sparkling Chair 6, 130

spinning, metal 10-11, 56-8

Spiral paper bowl 46

“Spirit of Ecstasy,” car hood ornament 224, 225

spray lay-up molding 152

spun carbon chair 158

stamping 59, 60, 61 “standoff forming” 69

Stanley DynaGrip Pro

screwdriver 206

Stanley Tools (UK) 206

stationary spindle swaging 106–07

steel 25, 27, 35

case hardening 272

centrifugal casting 162-3

chemical milling 38-9

electromagnetic forming 54-5

electron-beam machining (EBM) 24-5

forging 187-9

free internal pressure-formed (“FIDU”) 10-11, 73-5

hard 44

hot isostatic pressing (HIP) 170-1

hydroforming 143-5

incremental sheet-metal forming 57, 257-9

inflating 76

laser cutting 47, 74

metal injection molding (MIM) 216-8

metal spinning 56-7

plasma-arc cutting 33-5

pre-crimp weaving 111

wire EDM (electrical discharge machining) 44-5

steel junction, handrail system 143

stereolithography (SLA) 14-15, 239, 243, 246-9

Ströh, Anette 143

structural-reaction injection molding (S-RIM) 199

sublimation dye printing 262

suede coating 266

Superform Aluminium (UK) 70

superforming, aluminum 10-11, 70-2

surface finishing

see finishing techniques

Sykes, Charles Robinson 224

T-section, handrail system 143

table legs, “High Funk” 228

tables 53, 183

Around the Roses 262

Cinderella 21-2

Toki side table 52

tampo printing 265

teacup, Old Roses range 236

teapot, Wedgwood^® 140

Teflon^® 168, 278

textiles, calendering 90

thermal cutting 33, 48-9

thermal spray 271

thermoforming 10-11, 64-6

paper pulp 149, 150

thermoplastic elastomers (TPE) 207, 209

thermoplastics 95, 124. 153, 197, 201-2, 207, 211, 270

thermo-reversible gel 240-1

thermoset plastics 174, 176, 177, 207, 270

thermoset resins 103, 152, 153

thick-film metalizing 273

thin wall section, hollow components with 115-65

threading 18,

three-dimensional printing 240, 242-3

titanium 39, 44, 47, 48, 49, 171, 173

Toki side table 52

torch, Mini Maglite^® 18, 279

Toyota 258, 259

transfer molding 14-15, 153, 176-7

trees 112

see also plywood; veneers; wood

true centrifugal casting 161, 162

tubes 54, 143, 161

Tulip (Netherlands) 214

tungsten 39, 168

turning 10-11, 18, 20, 26-8, 30

two-shot molding see multicomponent molding

upset forging 188

urine bottle, disposable 149

vacuum-bag molding 152-3

vacuum casting 247

vacuum cleaner 260, 263

vacuum forming 64

vacuum infusion process (VIP) 12-13, 154-5, 177

vacuum metalizing 262

VAIO laptop computers 262

Valeo (Germany) 203

vapor metalizing 276

varnishing 169

vases, thin-walled 118

veneers 86, 112, 113

cross-laminating 80-1, 184

cutting 12-13, 83, 84, 112-3

furniture 83, 85, 113, 181

Verhoeven, Jeroen 21

Vernacare 149

viscous plastic processing (VPP) 14-15, 236-7

vitreous enameling 281

volatile organic compounds (VOCs) 268, 270, 271

Wade Ceramics (UK) 26, 27, 134

Wanders, Marcel 6, 130

water injection technology (WIT) 196-8

water-jet cutting 10-11, 35, 42-3

wax patterns 224-7

Wedgwood (UK) 7

plate 29

teapot 140

Wednesday Light 263

wet etching see acid etching

wet-bag pressing 172, 173

whistles 50

Acme Thunderer 50, 51

Whiteread, Rachel 134

wire EDM (electrical discharge machining) 10-11, 44-5

wood

inflating 184-6

laminated 87

turning 26

see also plywood; veneers; trees

Xylan 278

Zientz, Kristof 143

Zieta, Oskar 73, 74, 75

zirconia ceramic knife blades 170, 171

Acknowledgments

Thanks to Dani Salvadori, who has helped champion this idea since its inception. Many thanks also to Ishbel Neat, Lucy Macmillan, and Jennifer Hudson for their help with the laborious task of chasing permissions for the images. As always, a massive thank you to “my team” for this project: Hema Vyas, Hayley Ho, Anna Frohm, and the biggest thank you to Daniel Liden, who has been many things in the writing of this book, including researcher and adviser. Thanks also to James Graham for his wonderful illustrations; to Roger Fawcett-Tang for making this book so visually striking; Xavier Young not only for his photography but also for his inspired ideas and continued collaboration; to Russell Marshal for his technical appraisal; and to Alan Baker who, after almost 20 years, is still my “materials and process man”—it is a pleasure to have been one of your students.

A really big thank you to all at Laurence King Publishing, particularly Jo Lightfoot and Jessica Spencer.

A special thanks to my young sons Theo and Jerome, whose constant joy provided me with the motivation to deal with the frequent lack of sleep they both so generously encouraged. Lastly, thank you to my wife Alison who after 20 years continues to be my supreme creative inspiration, partner, and motivator. Here’s to the next 20 years, my love.

Picture Credits

The author and publisher would like to thank all contributors who have kindly provided images for use in this book. Every effort has been made to contact copyright holders, but the publishers would be pleased to correct any errors or omissions in any subsequent edition.

All illustrations by James Graham

Photographs by Chris Lefteri: pp. 20, 28, 31, 32, 66, 104 left, 110, 142, 206

Photographs by Xavier Young: 18, 24, 29, 40, 50, 64, 99, 108–09, 120, 130 top, 134 right, 140, 149, 170, 172, 174, 187, 209, 219, 231, 236, 275

18 By permission of Mag Instrument, Inc. MAGLITE and MAGLITE are registered trademarks of Mag Instrument, Inc.

21–22 DEMAKERSVAN

24 Courtesy of Arcam AB.

26 Wade Ceramics Ltd.

29 WWRD UK LTD.

33 Reproduced by permission of TWI Ltd.

38 left Sam Buxton, Mikro Man Off Road, 2002, 95lx35wx40h mm. Image courtesy of the artist.

38 right Sam Buxton, Mikro Man Player, 2002, 95lx35wx40h mm. Image courtesy of the artist.

40 Normann Copenhagen.

42 Design: Louise Campbell. Manufacturer: Hay

46 Fuminari Yoshitsugu

50 Acme WhistleCo.

52 Setsu & Shinobu ITO. FIAM Italia Spa.

56 Peter Mallet

58 Heatherwick Studio

59 Rexam Beverage Can Europe & Asia

61 & 62 Courtesy of Industrial Origami, Inc.

67 & 68 Courtesy 3D-Metal Forming B.V.

70 Image Marc Newson

73 & 74 All images Zieta Prozessdesign

76 Created by Stephen Newby/Full Blown Metals. Image taken by Joe Hutt.

78 Courtesy Sodra Pulp Labs

80 Lapalma s.r.l., via E. Majorana 26, 35010 Cadoneghe (PD), Italy.

83 Design: Komplot Design/Poul Christiansen & Boris Berlin. Production: Gubi, Denmark.

85 Photographs by Reholz GmbH.

86 right Neville UK Plc.

94 Photograph by Ida Riveros

96 Heatherwick Studio

97 Peter Mallet

99 © Exel Composites Plc.

101 Photographs by Daniel Liden, taken at RBJ Plastics in Rickmansworth, www.rbjplastics.com

104 right Courtesy of Apple Inc. Photographer: Doug Rosa

108-9. Permission for LKP to use image has been granted by Potter & Soar Ltd. who are part of the Aughey Group of companies.

112 Designer: Antoni Arola. Photograph by Carme Masià.

116 left Mathmos Airswitch Flask Lamp is a trademark and a patented technology owned by Mathmos—www.mathmos.com.

116 right Courtesy of Kosta Boda. Photographer Vassilis Theodorou

118 left Photograph by Goran Tacevski. The vases were developed with Mr. Karel Krajc, Head of the Technology Department of glassworks at Kavalier Sázava.

118 right Photographs by Craig Martin and Brian Godsman, property of Scott Glass Ltd.

120 Courtesy of KIKKOMAN CORPORATION.

123 Photographs courtesy of Beatson Clark Ltd.

124 Bruni Glass SPA copyright. Photograph by Bruni Glass SPA.

130 bottom Courtesy Marcel Wanders

134 left Wade Ceramics Ltd.

135 Courtesy of Diptech.

137 & 138 Courtesy Marloes ten Bhömer

140 Courtesy of Wedgwood

143 & 144 top. Courtesy of Darmstadt University of Technology

146 & 147. Sigg Switzerland AG

149 Courtesy of Vernacare

154 Courtesy of Polyworx.

Infusion of the Southernwind 100’ carbon/epoxy sailing yacht; technology designed and implemented by Polyworx BV.

158 Courtesy of Mathias Bengtsson.

159 Photographs courtesy of Goodrich Crompton Technology Group.

170 © KYOCERA.

172 NGK Spark Plugs (UK) Ltd.

176 By permission of Go-Ahead London

179 Seggiolina Pop, Magis, photo by Carlo Lavatori. Magis SPA, Z.I. Ponte Tezze – Via Triestina Accesso E, 30020 Torre di Mosto (VE), Italy. Tel: +39 0421 319600, Fax: +39 0421 319700, info@magisdesign.com

181 & 183. Photographs courtesy of Alias

184. & 186. Photographs courtesy of Malcolm Jordan.

192 Fraunhofer Institute Material and Beam Technology IWS, Germany.

196 Courtesy of BIC^® Cristal^®

201 Air-chair designed by Jasper Morrison. Air-chair, Magis, photo by Tom Vack. Magis SPA, Z.I. Ponte Tezze – Via Triestina Accesso E, 30020 Torre di Mosto (VE), Italy. Tel: +39 0421 319600, Fax: +39 0421 319700, info@magisdesign.com.

203 Courtesy Gianni di Liberto

206 Stanley UK Sales Ltd.

212 Courtesy IDT Systems

214 Courtesy of Tulip Computers.

216 Courtesy of Metal Injection Mouldings Ltd.

219 Courtesy Mattel. LOTUS, EUROPA and the Europa car design are the intellectual property of Group Lotus plc. N.B. The rights of Group Lotus plc extend to the design of the car embodied in the toy featured in work and the trade marks LOTUS and EUROPA. Group Lotus owns no rights in the toy itself nor in the photographs of the toy to be reproduced in the book.

222 Photograph Ida Riveros

224 Reproduced with permission of Rolls-Royce Motor Cars Limited. The Spirit of Ecstasy, Rolls-Royce name, and logo are registered trade marks and are owned by Rolls-Royce Motor Cars Limited or used under license in some jurisdictions. Photograph by permission of Polycast.

226 Photographs by permission of Polycast.

228 Courtesy of Olof Kolte

234 Marc Newson Ltd

236 WWRD UK LTD.

240 Homaro Cantu/Moto Restaurant, Chicago

242 Models produced by Mcor on the Matrix

300 file provided by Paul Hermon Queen’s University and photographed by Cormac Hawley

244 Photographs courtesy of the Centre for Rapid Automated Fabrication Technologies (CRAFT), University of Southern California.

246 Black_Honey.MGX by Arik Levy for .MGX by Materialise.

248 top left/right Patrick Jouin ID – Solid C1 – Patrick Jouin studio.

248 bottom left Patrick Jouin ID – Solid C1 – Patrick Jouin studio.

248 bottom right Patrick Jouin ID – Solid C1 – Thomas Duval.

250 Courtesy of Mimotec.

253 Photograph courtesy of Renishaw plc – www.renishaw.com

255 Courtesy of Cornerstone Research Group.

257 & 258 Photograph by Martin McBrien. Courtesy of Dr. Julian Allwood and University of Cambridge Dept. of Engineering

262 (Sublimation Dye Printing) Alessandro Paderni; (Vacuum Metallizing) left: Courtesy Tom Dixon right: Ida Riveros

263 (Flocking) Courtesy Miele & Cie KG; (Acid Etching) Courtesy Studio Tord Boontje

265 Courtesy Franc Fernandez and kxdesigners

267 Adrian Niessler and Kai Linke

269 (Self-healing coating) Courtesy Hyundai; (Liquid-Repellent Coatings) Courtesy p2i

270 (Ceramic Coating) Courtesy of SRAM LLC; (Powder Coating) Courtesy COLNAGO

274 Courtesy WHEELABRATOR GROUP

279 (Chrome Plating) Amendolagine e Barracchia Fotografi; (Anodizing) Courtesy VERTU

281 (Ceramic Glazing) Courtesy Porzellan Manufaktur Nymphenburg www.nymphenburg.com; (Vitreous Enamelling) Xavier Young