DEPARTMENT OF INDUSTRIAL DESIGN

Faculty of Architecture and Design University Putra Malaysia

PROJECT REPORT EXPERIMENTAL PROJECT-MIX AND FIX

IND 3201 DESIGN AND REALIZATION LAB I (GROUP 6)

Bachelor of Design (Industrial Design)

THIRD SEMESTER ACADEMIC SESSION 2010/2011

PREPARED BY 157902

YEO MEI YONG

FARIDATHUL FARHANA BTE CHE JOHAR 158514 PREPARED FOR : PN. SITI MASTURA BINTI MD. ISHAK EN. MOHD FAIZ BIN YAHAYA EN. NIK AIZAN NIK ABDULLAH

IND 3201 DESIGN AND REALIZATION LAB I Program Bachelor of Design (Industrial Design)

Acknowledgement
First of all, all the praises goes to the mighty God. Were also grateful as weve completed this project with the blessing from our parents, lecturers and those who are involved in this project.

Secondly, thanks to our lecturers who had guided us and giving advices to us about the project. They had giving us a very useful tips and supporting us in every step wed taken. By not letting us down and kindly motivate ourselves to finish this very challenging project, they also has teach us a lot about the field in experimental process. Apart from that, we had learnt about the ideas and impotency of raw material in each experiment we had.

Not to be missed, to our parent that always supports us in many ways especially in terms of financial support and relieving us from all sudden pressure that this project has bring up. From them weve learn how to control the pressure heated in order to finish the project. To all the sources who are willing to help us and give us the opportunity to interview them in order to get information. We are really appreciated that they actually spend some time with us just to make sure we get all the information right.

Lastly, all our friends that understand how the process was; tiring but yet very exciting especially in the experimental process, trying something new and share experience with us. It actually helps us in many ways. We also appreciated the time all of us spending time together in studio, helping each other, teaching how to make things flawless, just to ensure this project going to work perfect.

Thank you.

TABLE OF CONTENT
NO. 1 Project Mix and Fix Project brief 2 Procedure Introduction of procedure Main procedure 3 Experimental Process Equipment used List of materials Adhesive used Method and procedure Outcomes Recommendation and Conclusion 4 Appendices SOP form (Standard of Procedure) 5 6 7 Conclusion References Glossary 21 22 25 20 15 4 INDEX PAGE 1

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Project Mix and Fix

This project requires students to be in group of two, we are allowed to choose our own partner in order to ensure the project conducted smoothly. This is an experimental project which demand all the students to create new product made by several of raw material such as, banana leaf, clay, coconut fibre, turmeric and sand. In spite of using raw material, students also permitted to use some of recycled material such as paper and tissue. It is a necessity for us to know the function of each material we use so we can put some ideas on expected result as the conditioned for these product to pass is, it can carried at least 3kg of weight and the size is about 1 feet x 1 feet maximum. As to make it more valid or to get some extra marks, we can make some finishing in term of colour, textures and shape of the product. Another aspect that need to be emphasized is that every experimented material must be test by students according to the SOP form (Standard of Procedure) given. Task given meant to do a basic experiment onto multiplicity of raw or recycled material as to renovate it into new media. The objective of the assignment is for us to discern and appreciate what nature resources and recycle items. Thus, this report will be deliberating and reporting about the experiment that group six had done. It will intricate about the material, adhesives, procedure, results and expected result further to propose usage. This report is a step and guidance for our group work to run efficiently and footage of what we have been experiment. This report has the ability for us to look back and consequently using alternatively methods to create new material. Besides that, it can be a reference for other readers to refer as in future for their works. This mission has the duration of 7 weeks.

These are the timeline of the project: Date Accomplishment Project brief given by lecturers. The briefing includes date of submission, material that can be used, proper procedure for the experimental, discussion about academic trip to help us gained more information and distribute SOP form (Standard of Procedure). We have been given the opportunity to choose our partner in this project. Each group presented their list of materials and adhesive in the class. We have discussed with lecturers and all members in class about the materials and adhesive that suitable to use later on our project. We have been given a lecture about model making process and tips on choosing the right material for our project. Were then discussing about our list of materials and proceed with five different procedures to be experimented with. Our class went to Kompleks Kraf at Jalan Conlay, Kuala Lumpur. In spite of that, we also visit Royal Selangor International at Setapak Jaya. These trips are very profitable as we gained so much information that might help us during this project. Each group have showed their sample product resulting from the experimented procedure proceed from last week. Some of our experimented product has been rejected; some of them need to be improvised. We are then made a few improvements toward our procedure and the final procedure that can be proceed for assessment day has been made. We are working on our experimented procedure and begin our preparation for the assessment. Our product has been made in expectant size and we also prepared several different procedures that have been made during discussion process among our group. Day of assessment. Things that are submitted in this day

12/9/2011

19/9/2011

26/9/2011

3/10/2011

10/10/2011 17/10/2011

24/10/2011

31/10/2011

including panels, technical sketches, reports, sketches and the final product itself. As conclusion,

Design brief
Project Theme Duration : : Mix & Match

7 weeks

Project Description : Students are required to do experiment onto range of material that has potential to turn into new media. Every experimented material must be tested by student according to the SOP form given. The total experiment done must not less than 5 times. The size of final outcome is basically (L) 1 x (W) 1 x (H) 5cm maximum.

Design Statement : To reveal the rich fullness of nature and sources to invent new material as to substitute limited material or other unrecyclable material.

Design Objectives : To propose a new media that nature friendly. To adapt the new media onto design of production.

Introduction of Procedures

Our study was conceded by starting exploration on website. A trip to Malaysian Handicraft Development Corporation (MHDC) was done also contributed in our experiment too. By surfing onto websites, we found that the common grass that we see has fiber too and has the budding to convert into new media. We also have several experimental procedure made before we decide to finalize the procedure. These procedures have been discussed with lecturers and among our group using several of materials and some adhesive. List of material used during the project: Bougainvillea, Bunga telang, cinnamon, coir, facial cotton, grass, lotus stem, mango skin, sawdust and root of morning glory. Adhesive: Bleach, PVA glue and sugar.

Experimental procedure
Experiment 1
Overall aims and specific objective Aims: To make paper from grass Objective: To save the resources and pollution by recycling. Base Adhesives Grass, Baking Soda PVA Glue Instrument Blender, cooker, filter, pot, stirrer, container Procedure Used 1. Cut the grass and blend it 2. Cook the blend grass 3. Digesting the grass in baking soda 4. Filter it and let it dry 5. After it dry, apply PVA glue on it Expected Color Spongy , flammable ,dusty Sap green Results Color Spongy, soft, not hard Light green, yellow ochre Recommendations Replacement of sponge, duster Conclusion Results Materials -

It is soft, but not long shelf of life. It is dusty too if not well take care. Besides, it is brittle. It is not the best new media that have made.

Experiment 2
Overall aims and specific objective Aims: To make a hard material Objective: To save the resources and pollution by recycling. Base Materials Adhesives Cinnamon - PVA Glue Instrument Compressor, mold Procedure Used 1. Align the cinnamon closely 2. Apply glue between each cinnamon 3. Apply glue on top of whole material 4. Wait till the glue dry Expected Color Strong, hard material, can support heavy things but < 3kg Light brown Results Color Brittle, hard & strong but weak bond, wood texture, nice smell brown Recommendations As cooking pad, if use many can be structure as dcor furniture, as base structure Conclusion This media results a strong and hard characteristic, with the nice smell. If there is a better bonding agent, this media sure fallouts a stronger material - Red Results -

such as MDF.

Experiment 3
Overall aims and specific objective Aims: To make a hard material Objective: To save the resources and pollution by recycling. Base Adhesives Star - PVA Glue Instrument Compressor, mold Procedure Used 1. Align the star anise closely 2. Apply glue between each star anise 3. Apply glue on top of whole material 4. Wait till the glue dry Expected Color Strong, hard material, can support heavy things but < 3kg brown Results Color Brittle, not strong, wood texture, nice smell, easily break brown Recommendations As dcor furniture, as accessories Conclusion This media results a weak and brittle characteristic, with the nice smell. It is totally not suitable for any structure; it just can be used as a dcor. - dark Results Materials anise

Experiment 4
Overall aims and specific objective Aims: To make a soft, flimsy material Objective: To save the resources and pollution by recycling. Base Adhesives Root of morning glory PVA Glue Instrument Brush Procedure Used 1. Cut the root into same length 2. Start weaving into mat 3. Apply glue on base of whole weaving 4. Wait till the glue dry Expected Color Strong, elastic material, can support light things Light brown Results Color Not strong, wood texture, easily to break Yellow ochre Recommendations As floor mat, table mat, can be weave into bags. Conclusion This media results a weak and brittle characteristic, but after weaving, they become strong. It is totally not suitable for any structure; Results Materials -

Experiment 5
Overall aims and specific objective Aims: To make a hard supportive block that can hold load. Objective: To use as lifter or as base lining mate. Base Adhesives Coir, sawdust, facial cotton and star anise. Sugar Instrument Pot, Stirrer, Spoon, Cooker. Procedure Used 1. Heat the cooker and pour sugar in it, let it melt and become viscous. 2. Add in coir and sawdust in it and stir it until the sugar cover both coir and sawdust. 3. Flatten the mixture while it still hot, let the heat cool down slowly. 4. Put cotton around it in reasonable thickness. Expected Color Hard, low melting point, thick as block. Brownish Results Color Can hold load but easy to break Dark brown Recommendations Use as base lining mate. Conclusion Easily break but can hold load and use as mate or base lining, cannot be used to carry load from in far distance. Results Materials -

Experiment 6
Overall aims and specific objective Aims: To make a soft/flimsy material Objective: To save the resources and pollution by recycling. Base Adhesives Lotus - PVA Glue Instrument Cutter, water Procedure Used 1. Cut the stem out of the lotus 2. Cut small portion of the stem 3. Put the small part apart from the longer part to extract the fiber out 4. Twist the fiber and made it into string Expected Color Strong, soft like cloth material White Results Color Soft, easily to be pull, like cloth Can be dye easily Recommendations As cloth for fashion, wrappers Conclusion This media results a weak and soft characteristic, with the nice feels of touch. It is totally not suitable for any hard structure; it just can be used as cloth after knit the string into fabric. Due to some places dont have many of lotuses, It is consider as expensive material and it takes lots of works to Results Materials stem

fabricate it.

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Experiment 7
Overall aims and specific objective Aims: To make a soft/flimsy material Objective: To save the resources and pollution by recycling. Base Materials Adhesives Plastic - none Instrument Iron , paper Procedure Used 1. Flatten the plastic 2. Put the plastic in between paper 3. Start ironing until the plastic turn into fabric 4. Overturn it and iron till no bubbles. Expected Results Color Strong, soft like cloth material on plastics color Results Color Not soft, stretchy, not so easily to be tear, waterproof original color Recommendations As flower wrappers , gift wrapper, raincoat, umbrella Conclusion This media results a characteristic of fabric, but its hard & rough than fabric. It is totally not suitable for any hard structure; it just can be used as wrappers. The best suggestion is raincoat or umbrella. - Lighter than - Based

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Experiment 8
Overall aims and specific objective Aims: To make paper from mango skin Objective: To save the resources and pollution by recycling. Base Adhesives Mango skin, bunga telang bleach Instrument Blender, cooker, filter, pot, stirrer, container Procedure Used 1. Peel the mango skin 2. Blend the mango skin & bunga telang 3. Bleaching the mixture 4. Washing the mixture 5. Filter it and let it dry Expected Color Paper like material, easy to tear off, flammable green Results Color Paper but, flammable, easy to tear, not hard ,dull, rough texture brown Recommendations Cards, packaging, paper bag, book cover Conclusion Addition of layer will contribute to make the sheets harder. This paper is impossible to write on it using a ballpoint pen. The nice texture makes it Results Materials -

well as an outer layer.

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Experiment 9
Overall aims and specific objective Aims: To make a hard material Objective: To save the resources and pollution by recycling. Base Adhesives Coir -PVA Glue Instrument Brush, mold Procedure Used 1. Layer the coir evenly 2. Apply PVA glue on top of the coir 3. Repeat the step until the layer is thick & hard 4. Wait till the glue dry Expected Color Strong, hard material, can support heavy things brown Results Color Dusty, spongy ,not easy to break, can be cut but hard to shape brown Recommendations As sponge, sofa, cushion. Conclusion This media results a strong and spongy characteristic, but after long time, they become sooty. It is totally not suitable for any outer structure; the best propose usage is as sponge or cushion. -shiny Results Materials

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Experiment 10
Overall aims and specific objective Aims: To make paper from Bougainville Objective: To save the resources and pollution by recycling. Base Adhesives Bougainville, -none Instrument Blender, cooker, filter, pot, stirrer, container Procedure Used 5. Take the bougainvillea and blend it 6. Add in the kenaf and blend 7. Filter it and compressed it to flatten 8. Let it to dry Expected Color Paper like material, easy to tear off, flammable red pink Results Color Paper but a easily to tear, flammable, rough, brittle dark brown Recommendations Packaging, paper bag, book cover, bookmarks Conclusion Addition of petals will contribute to make the sheets more beautiful. This paper will shrink under high temperature. It shall be coated by a layer of adhesives to prevent it from shrink. Results Materials hibiscus

Overall aims and specific objective Aims: To make paper from grass Objective: To save the resources and pollution by recycling. Base Adhesives Grass, - None Instrument Blender, cooker, filter, pot, stirrer, container Procedure Used 1. Cut the grass and blend it 2. Cook the blend grass 3. Blend the kenaf 4. Mix the grass with the kenaf 5. Filter it and let it dry Expected Color Paper like material, easy to tear off, flammable olive green Results Color Paper but a little bit elastic, flammable, easy to tear, not hard green Recommendations Letter paper, cards, packaging, paper bag, book cover Conclusion Addition of petals will contribute to make the sheets more beautiful. This paper is highly permeable by ink, but it is possible to write on it using a ballpoint pen. If you want to reduce the absorbency of the paper youve made, soak it in a solution of water and gelatin and then let it dry again. - olive Results Materials Kenaf

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Some of the experiment conducted:

Coir glued with PVA glue, we layered the coir to make it harder.

Cinnamon are align together to give it a shape that can support weight.

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Star anise are arranged to get a shape. It then glued with adhesive to ensure the capability of it to hold a load for as expectant.

Coir and sawdust are mixed together in a cooker. Sugars are used as adhesive component. The colour becoming dark depends on how long we left it in the cooker.

PROCEDURE
For the proceeding experimental product, we conduct the procedure all over again but using the expectant size and thickness that are preferred for a presentation. These are the procedure in making the product:

1. We cut the grass and rinse it until it become soft, easy to tear. We unsoiled the grass and clean all the dirt to ensure it will not affect our further step in making the Hard Grass. 2. The grass is blend until it become shrill.

3. After blending the grass, we cooked the grass. This process intended to evaporate the grass and one of a way to dry it. 4. The next step is to blend the kenaf similarly to the grass until become shrill and fine.

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5. The kenaf is then mixed with the grass earlier. 6. The mixture is then filtered and placed into a mold. We exposed the mixture under the sun and let it dry completely for bonding process.

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OUTCOME
EXPECTED RESULT
Filmsy, enough to embrace a weight, flammable.

RESULT
Thin, flimsy, flammable, easy to tear off, olive green in colour.

REPARATION
We have increase the thickness of the product during the process. By doing this, the mixture take a longer time to dried under the sun. It takes days before it completely dried out. The result after doing some reparation is: Thick, spongy, hard enough to support weight, flammable, olive green in colour.

RECOMMENDATION
Addition of petals will contribute to make the sheets more beautiful. This paper is highly permeable by ink, but it is possible to write on it using a ballpoint pen. If you want to reduce the absorbency of the paper youve made, soak it in a solution of water and gelatin and then let it dry again. In addition, it can be shaped according to the mold, the thickness can be adjusted.

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APPENDICES
SOP FORM (STANDARD OF PROCEDURE).

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CONCLUSION
From experimental process we have been through, it is obvious that to make a very hard product, we should not depend on the fibre to glue to each other. We need to add some adhesive in order to make sure its not brittle. We have gained a lot experiences during this project, we also noticed that it is essential for us to use some sort of fibre-present material since the fibre is strong in term of bonding. In addition, we add some adhesive such as PVA glue, sugar and bleach just to make it steadier. During the project, we have been observed experiment conducted by other groups and find several more substance that can be used as adhesive. The adhesive chosen to mix with the material is as much as important as choosing the material itself. Apart from that, we also learned that the method used give a huge impact in success and failure for the product to reach the expectant level needed in this project regulation. Not to be missed, likewise the main material and adhesive component, the addition materials for decorative usage did give some impact in finishing the product as we need a preventative product. It also helps us in gaining an extra mark for the project. We can conclude that, each material has its own characteristic. Grass is a form of fibre, they tend to be magically bonding together yet their surface are spongier than and not as hard as we expect it to be which is dissimilar to the coir and sawdust which can become harder if they mixed together. The method of heating and melt is not suit for our procedure as it can burn our chosen material. We tend to use mix and dry method rather than heat and melt process. It is important to understand characteristic in each material in order to make sure the mixture is an exceptional combination. We did this project not only to fulfil the project requirement, but we also have exposed ourselves with raw material and in spite of wasting it, we use it to make new media. They might be a potential new material that can be used in the industries.

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REFERRENCES
http://psasir.upm.edu.my/498/

Properties of Kenaf (Hibiscus Cannabinus L.) Bast Fibre Reinforced Unsaturated Polyester Composite
Aw Yeong, Chee Hong (2004) Properties of Kenaf (Hibiscus Cannabinus L.) Bast Fibre Reinforced Unsaturated Polyester Composite. Masters thesis, Universiti Putra Malaysia.

PDF 116Kb

Abstract
The main purpose of this research is to exploit new bio-fibre resources for the structural composite industries. Kenaf bast fibre was combined with thermosetting resin matrix to produce advance composites and its mechanical and dimensional stability properties were investigated. Unsaturated polyester was used as matrix resin in this project which consist 44-48% of styrene monomer and form gel in 24-30 minutes with 1% methyl ethyl ketone peroxide. Biological retting and chemical retting were introduced to prepare the fibre. In biological retting, the bast layer of kenaf was submerged into a water-bath filled with sandy soil (pH = 8.9) and water for 3 days under constant temperature of 30 2 C. For chemical retting, the bast layer is submerged in 5% sodium hydroxide (NaOH) and boiled under high temperature (80 C) for 75 minutes. Modified water retting reduced the retting time to 3 days compared to normal water retting process which required 5 to 30 days. However, chemical retting produced weaker fibres due to the extreme processing condition. The kenaf bast fibre was well incorporated in the unsaturated polyester resin matrix and successfully hot-pressed into panels. The composites were fabricated using unidirectional and cross-ply lamination with different fibre volume fraction (40%, 50% and 60%). Chemical analysis, mechanical tests, Izod pendulum impact test and analytical test were carried out. Specimens were further observed under Phillips XL30 scanning electron microscope (SEM). Generally, the main effects of fibre content, lay-up method and fibre type significantly influenced the properties of kenaf bast fibre reinforced unsaturated polyester composites, except the fibre type has no significance influence on the impact resistance, water absorption and thickness swelling of kenaf composites. However, interactions of the main effects were dominated in each mechanical and dimensional stability properties such as the influence of interaction between fibre content - lay-up and fibre type - lay-up method. Overall, biological retted fibre composites showed better physical and mechanical properties compare to chemical retted fibre composites at the same fibre content and lay-up method. The tensile strength and flexural strength of 60% fibre content composites with biological retted fibre was 232 MPa and 248 MPa, respectively.

Item Type: Thesis (Masters) Subject: Kenaf - Technological innovations Chairman Jalaluddin Harun, PhD Supervisor:

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Call ITMA 2004 2 Number: Faculty or Institute of Advanced Technology Institute: ID Code: 498 Deposited INVALID USER By: Deposited 15 Oct 2008 01:09 On: Last 06 Jan 2011 12:08 Modified:

http://www.springerlink.com/content/uq56071775w307j0/

Characterisation of Grass Fibres

M. Sfiligoj Smole, T. Kree, S. Strnad, K. Stana Kleinschek

and S. Hribernik From the issue entitled "Special Section: Polymer Fibres 2004"

Abstract
The elementary grass fibres were isolated from different grass and legumes sorts, i.e. Ryegrass (Lolium hybridum Gumpenstein), Wheat straw, Trefoil (Trifolium pratense) and Lucerne (Medicago sativa). The fibre-samples were obtained in a bio-refinery, after the liquid phase containing proteins and lactic acid was eliminated from the ensiled and green grasses, respectively. For the isolation of elementary grass fibres different processes were used. The morphological characteristics of stems and leaves of different grass species were microscopically observed. On the microscopical stem and leaves cross-section samples the quantification of fibres sclerenchyma cells was performed. The quantitative analysis was carried out in order to obtain basic quantitative data on grass fibres, such as area of the single fibre or group of fibres,

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diameter of a single fibre or group of fibres and distances between the most distant and least distant points on the area of the fibre. Measurements were made using a Carl Zeiss software KS 300, which runs on a computer connected to the image analysis equipment consisting of a microscope and a digital camera. In addition to, geometrical and mechanical properties of isolated fibres and fibre bundles were determined. Due to the grass history, i.e. deformations and damages caused by the treatment of grasses in the bio-refinery, maturity grade, grass or legumes type and conditions during grass growth, the plant structures vary considerable in their properties.

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GLOSARRY
Adhesive
Tending to remain in association or memory; tending to adhere or cause adherences; prepared for adhering. - Adhere: to hold fast or stick bu or as if by gluing, suction, grasping, or fusing; to bind oneself to observance.

Cinnamon Any of several Asian trees (Genus Cinnamomun) of the laurel family;
an aromatic spice prepared from the dried inner bark of a cinnamon; a light yellowish brown.

Experimental Of, relating to, or based on experience or experiment; a serving the

ends of or used as a means of experimentation <an experimental school>; relating to or having the characteristics of experiment: tentative <still in the experimental stage>. - Experiment: a test, trial <make another experiment of his suspicion Shakespeare>; a tentative procedure or policy.

Kenaf An African hibiscus (Hibiscus cannabinus) widely cultivated for its

fibre; also: the fibre used especially for making paper and cordage. - Cordage: Ropes or cords: especially the rope in the rigging ship

Recycle To pass again through a series of changes or treatments: as; to

process (as liquid body waste, glass, or cans) in order to regain material for human use; recover; to reuse, remake.

Raw material
Crude or processed material that can be converted by manufacture, processing, or combination into new and useful product; something with a potential for improvement, development, or elaboration.

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