Introduction

For this project, I learned the process of molding and casting to create an object. From the start, I knew I didn’t want the final pieces to resemble the shape of my fingers—I’ve never liked their small, stubby appearance. Because of this, I treated the molding and casting process as a means to an end: creating a blank canvas that I could transform into something more minimalistic during post-processing. This approach not only made the assignment more personally meaningful but also allowed me to focus on designing pieces that could be practical and visually appealing for my use.

Molding

I began by mixing 33 g of alginate with 150 mL of water to prepare the hydrogel. Once mixed, I placed my finger into the hydrogel for about 10-15 minutes until it polymerized. After the material set, I carefully removed my finger, preserving the mold’s shape.

Casting

With the alginate mold ready, I mixed plaster of Paris in a 1:2 ratio and poured it into the mold. After allowing the plaster to cure overnight, removing and pouring more plaster mixture, and waiting all day, I had two original casts to work with. Unfortunately, one of these broke during post-processing due to excessive sanding. Thankfully, I had saved my mold, so I remade the mixture and cast a new piece. This setback meant spending additional time—over four hours in total—but it allowed me to refine my approach to the next steps.

Post-Processing

The post-processing phase was the most significant part of my project. I used 80-grit sandpaper to hand-sand both pieces, being more careful to avoid repeating my earlier mistake. My goal was to erase the “finger-like” quality of the casts and transform them into sleek, minimalistic shapes. Once I achieved the desired look, I moved on to spray painting.

Finishing Touches

I spent considerable time debating the color and finish of the pieces. Wanting something simple and functional, I chose a stone-gray spray paint and a matte clear coating. I applied three coats of gray paint, waiting 20 minutes between layers, and then (after waiting three hours) applied two coats of matte clear finish, waiting 30 minutes between each. After letting the final coat cure for three additional hours, I considered the hangers complete.

The Workspace

Throughout the project, I ensured the workspace was cleaned after each step, especially given the mess created by sanding and casting. The vacuum cleaner and I were especially good friends these last couple of days, but, like I always say, this part of the process is really important, if not the most important one. 

Cost Estimation

Type	Description	Cost	Source	Quantity	Total
Materials	Alginate	$12.5/lb	Amazon	~75 g = 0.165 lbs	$2.0625
	Plaster of Paris	$9.85 per 8 lb	Amazon	~150 g = 0.33 lbs	$0.4065
	80 Coarse Sandpaper	$9.90 per package (25 sheets)	Home Depot	1 sheet	$0.396
	Gray Spray Paint	$5.98 per can	Home Depot	⅕ can	$1.196
	Matte Clear Coating	$6.50 per can	Home Depot	⅕ can	$1.300
Labor	Prototyping Engineer	$25/hr	Indeed.com	5 hours	$125
Overhead	Quality Control	$22.50/hr	Glassdoor	½ hour	$11.25
Total	$141.611 (2 hangers) $70.8 per piece

Reflection

One thing I realized during this project is how much time goes into waiting for materials like plaster to cure. In my case, I didn’t include this “dead time” in my workflow estimation because I used it for other activities, like completing homework for other courses. On an industrial scale, these downtimes would likely be utilized for parallel tasks or other projects, optimizing the use of time and resources. In my situation, this multitasking allowed me to stay productive, but it also highlighted how critical efficiency and task management are in manufacturing processes.

This project was a creative and technical challenge that mirrored my approach to the course. I like to push myself to create things that are both functional and personally meaningful. By reinventing the shapes of the casts and transforming them into usable hangers, I not only met the assignment requirements but also created objects that feel uniquely mine. This experience reinforced my belief in leveraging technical skills to make custom, practical solutions, even in small projects like this.