These laser cut cards have pieces that pop out and snap together to create playful animals. The critters have contact information on them for a lasting impression.

Work began October 2009.  I’ve been developing a more reliable clasp system for the pieces when they snap together and have also been working on a lot more animals.

It’s here, I received my latest prototypes this morning after glassblowing.  After classes tonight I spent a few hours forming each spoon and fork and preparing them for the final display.

I uploaded a few shots I took during the process, and as always, let me know what you think.

Check it out at the Ponoko Showroom here

Also, check out the Ponoko Blog, thanks to Duann for the post

Today my friend Kamilah helped me with getting some context shots of Phillyware in action.  We used the bright green colors in the salad to contrast the black fork.  I’m planning on taking a lot more photos once the final models arrive, but for now I really wanted to just get a few context photos.

While waiting back for my second round of prototypes from the laser cutter, I’ve been working on forming my first round so I can have practice for when the final ones arrive.  Pictured above is the spoon being formed in the mold, which I must say has to be the hardest thing I’ve modeled in 3D so far.  After the CNC milled out my design into the foam, I lined it with a thin layer of felt, to keep the surface of the hot acrylic nice.

The spoon and the fork required forming, and I learned a lot from these early forming attempts.  Tines on the fork have to be carefully watched, as well as handle/tab shape while hot.  Any warping or distorting of the handles really presents a problem.  When attaching the tabs into the warped slots, the tabs don’t line up and the design doesn’t work.

The changes for the next round are exciting, and once I get them back I’ll begin working on them.  For now our class has the first round of prototypes on display in our department, but we’re planning to revamp the display once we all make our adjustments before the final show.

Check out more updates at my previous Phillyware post

Put a lot of work into remodeling and re-rendering the new, more accurate forms over the past few days.  I’m sending for the second round of prototypes tomorrow, I improved the slot and tab design, added a cutting edge to the knife, and modified the shape of the spoon bowl to reflect the new renderings.  Kiki already slumped her flatware into their forms, and she even made a video of the process.  300 degrees, 5 minutes

Check out some of the new renderings at my coroflot online portfolio

On friday, I received my first round of laser-cut flatware back from Ponoko, a company that offers laser-cutting services in New Zealand.  I have been pretty anxious to receive these, as I spent a good amount of time designing and planning for them

Initially, I was hoping to sell the final designs online, thinking that it may appeal to Philadelphians that want to eat in style.  However, the intricacy of the cuts needed in between the tines of the fork presented a problem for the stainless steel.  A representative from Ponoko emailed me saying that their laser cutter can’t do such small details, as the material begins to heat up and spatter, thus failing to define the shape I need.  Also, they don’t engrave designs into metal yet, so I couldn’t get that Phillyware logo (above) engraved onto the handles of my pieces.

With this information in mind, I switched to jet black acrylic, a material that has been mastered by the Ponoko team.  I am worried about the functionality of the flatware in plastic as opposed to stainless, but I’m going to continue to pursue getting these done in stainless in the future.  Perhaps a water-jet cutter, as they do not heat up the material as they cut.

Anyway, here are some pictures of the laser-cut pieces that I received back.  I created forks, knives, and spoons with many variations on each.  I tried different ways to represent the Phillyware logo, and I tried some pieces flat and some pieces with 3D handles (slot and tab design that clicks into place).  Please provide feedback on both the usability of acrylic flatware, the designs in general, and anything else on your mind after viewing these.

I was happy with the detail achieved by the laser on the fork tines, and I am a little uncertain with the quality of the engraving requested.  It seems a little strange, almost like a checker-board pattern if you look close enough.

Also, these are simply the pre-forms.. they have yet to be formed into the proper shapes that will cradle food properly like real flatware does.  They are flat coming from the laser cutter, as they are cut from flat sheets, but once formed I’ll be taking context shots of them and posting them up here.  I’m going to have to send away again, as I’ve learned a lot from getting these designs back.

Coroflot link: http://www.coroflot.com/westhomas/phillyware_laser-cut_flatware

Phillyware represents the city of Philadelphia in style.  These unique forks, knives, and spoons remind the people of Philadelphia to enjoy their local, fresh food options.

The molds were milled using a CNC router with urethane foam.  Currently, I’m using acrylic, but in the process of getting the capability to do them in stainless steel.

// rendering of the stainless steel version I’m hoping to create soon

Acrylic. Laser cut and formed in custom molds. January – February 2009