New Zealand designer Phil Cuttance recently presented his Faceture object series, which include vases, lampshades and a table. Each of these objects is individually created by casting a water-based resin into a handmade mould. The objects are produced on a specially devised machine, making every piece unique.
The process is simple: first the mould of the object is hand-made by scoring and cutting a sheet of 0.5mm plastic sheet, which is folded, cut and taped into the overall shape of the product to be cast. The mould's final shape, and strength, is dictated by which triangular facets are popped in and out. "I do this each time I ready the mould for the next object, meaning that no two castings are the same," Cuttance says. "I then mix a water-based casting resin that is cast in the mould where it sets solid."
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The Faceture machine in use. Photo by Petr Krejci
The resin is poured into the hollow mould and rolled around to coat and encase the sides. After setting, a second, different coloured measure of resin is poured into the same mould, and swirled around inside, over the first. When it has set, the mould is removed to reveal the solid set cast piece.
The Faceture machine in use. Photo by Petr Krejci
The Faceture machine's construction is simple, screwed together to allow it to be flat-packed for shipping. Wheels make the machine portable within a working space. The shelving beneath provides storage for freshly cast pieces, and room for the casting stool to be stored. The "hopper" holding the Jesmonite powder is made simply from polypropylene sheet, in the same way as the moulds.
Phil Cuttance, Faceture. Photo by Phil Cuttance, Petr Krejci
The casting jig at the back of the machine allows Cuttance to peer into the mould and control the flow of the fast setting Jesmonite. This results in an even and economical casting process, leaving a thin yet strong wall thickness. It can be attached at two different widths to accommodate different sized moulds (for example, vases or a table).
Phil Cuttance, Faceture process. Photo by Petr Krejci
Phil Cuttance, Faceture. Photo by Phil Cuttance, Petr Krejci
Phil Cuttance, Faceture. Photo by Phil Cuttance, Petr Krejci
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