Developed a casein-based bioplaster from curdled milk, marble dust, pumice, and sodium bicarbonate, then used it as a composite layup material over a hand-fabricated steel and timber frame. The project spanned material science R&D, structural design, and full fabrication.

Hand-bent 3mm steel rod ribbing, TIG and spot welded into a skeletal framework with concave/convex curves and large overhangs. Timber seat and internal legs acting as bulkhead and stringers, borrowing from boat-building construction. Bi-axial hessian and multi-axial hemp wrapped over the ribs as reinforcement, mimicking fibreglass layup. Three-stage bioplaster lamination: low-viscosity fibre impregnation, structural fill layers, and pumice-pigmented gel coat finish. Iterative material development through compression tests, adhesion trials, and stress simulations across 3+ formula versions to resolve shrinkage, mould growth, and cracking. Beeswax waterproof seal. Sanding and surface finishing (80 to 320 grit).

Materials: milk, marble dust, pumice, sodium bicarbonate, beeswax, hessian, hemp, steel, timber.