Introduction: Alex's Design: Plastering

To be a successful designer and a successful problem solver, it's important to know about as many different materials and manufacturing processes as possible. By understanding how materials can be manipulated we are able to create exciting forms and create products that solve problems in more innovative and creative ways.


- 2-3 Sheets of High Impact Polystyrene

- Scissors

- Clear tape

- Ruler

- Pencil or Pen

- 2-3 Sheets of blank Paper

- 2-3 cups of water

- 2-4 cups of plaster powder

- 1 bucket

Step 1: Gluing (Mold Step 1)

Put 1 high impact polystyrene sheet on a flat surface and then glue the blank sheet of paper (making sure the sides are aligned with each other.

Step 2: Measuring (1/2) (Mold Step 1)

Grab your ruler and place it on the bottom of your paper and then get a pencil to trace a mark on the 25cm line.

Step 3: Measuring (2/2) (Mold Step 1)

Rotate the high impact polystyrene and then place the ruler below the sheet of paper. For a quicker method put the 11cm mark on the corner of the paper and then trace with a pencil where the 1cm mark is (either way just trace the 11cm mark because that's our height of the product)

Step 4: Tracing (Mold Step 1)

after leaving the measurement (25cm horizontally and 11cm vertically), using a ruler and pencil, draw a straight line across and up, making the lines meet.

Step 5: Cutting (Mold Step 1)

Using scissors cut out the traced lines, leaving you with a 25cm x 11cm rectangle

Step 6: Measuring (core Step 1)

Grab your second sheet of high impact polystyrene and glue a new sheet of blank paper (same with the rectangle).

Step 7: Tracing (core Step 1)

using a ruler and pencil, (horizontally) trace a 5cm x 7 cm rectangle, repeat step 7 another 2 times leaving you with 3 5cm x 7cm rectangles that will be used for the core. Make sure that all three of them are side by side to save the high impact polystyrene for another step.

Step 8: Cutting (core Step 1)

After finishing tracing out the 5cm x 7cm rectangles you will need to cut them. Use scissors for this process and make sure you cut all 3 of them without trimming the original size.

Step 9: Measuring (core Step 2)

With the leftover high impact polystyrene, glue another blank sheet of paper on the corner of the high impact polystyrene.

Step 10: Tracing (core Step 2)

Using a pencil and ruler, trace a 5cm sided triangle (all sides are even) with a ruler on the blank sheet of paper (make sure that you start from the corner of the paper).

Step 11: Cutting (core Step 2)

after successfully tracing out the 5cm sided triangle, use scissors to cut out the traced lines on the high impact polystyrene.

Step 12: Gluing and Tracing (Mold Step 2)

Use the leftover high impact polystyrene and glue a blank sheet of paper on the corner of the high impact polystyrene and trace a 11cm x 11 cm square

Step 13: Cutting (Mold Step 2)

After tracing, cut your 11cm x 11cm square

Step 14: Reminder:

For those of you who want to add text to your product as I did, make sure to cut out 2-3 cm long for one letter because if it's too big it won't fit in the mold. And make sure to mirror the text or else it will be in reverse like my one.

Step 15: Assemble (taping)

Get cellar tape and tape all the edges as shown above. Make sure you have a triangular prism and a semicircle

Step 16: Assembling & Plastering

Once all is taped put the triangular prism in the mold and prepare for your plastering phase.

Step 17: Plaster and Casting

Get 2-3 cups of water and 2-3 cups of plaster powder

Step 18: Plastering

Pour the water in the bucket first then add the powder

Step 19: Stirring

Get your spatula and stir the mixture until it feels viscous.

Step 20: Pouring

Get your mold and pour the mixture into the mold then add your core later.

Step 21: Drying

Once your mold and core are in the mixture tape the core to make it stay in place then move the mold to another area to dry for 24.2 hours.

Step 22: Final Product 1/2

Once the product is dried, sandpaper the rough edges to make it feel smoother.

Step 23: Final Product 2/2

feel free to make any adjustments to make the product look and feel better.