Fascinating production method: hot wire extensions


Looking at these non-digitally made objects, could you tell how they were made?

Fabio Hendry, designer and materials researcher based in Switzerland, has imagined a new production method to create them. The method and its company have the same name: Hot wire extensions.

“Exploration and sustainability are at the heart of our philosophy and the Hot Wire Extensions process is designed with this in mind,” the company writes. “Using 3D SLS nylon powder, a material that is currently not recycled and inspired by the way a vine grows around a tree, we repurpose the material to create organic bone-like structures built around of a thread.”

“The process begins with creating a form using nichrome wire, which sits in a container. The container is then filled with Hot Wire Extensions’ unique nylon powder and sand formula. A current Electricity is sent through the wire, causing the surrounding nylon to melt and grow around the shape.The longer the current flows, the larger the fused material becomes, giving infinite flexibility in length and width.

“The process is made possible through collaboration with [eyewear manufacturer] Götti Switzerland, which supplies us with nylon waste.”

There’s a fascinating insight into the process (video not embeddable) here.

Rain Noah

I’m a lapsed industrial designer. I was born in New York and thought I would die there, but a few years ago I left New York to live on a farm in the countryside with my wife. We have six dogs.


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