Theatre Design & Technology - Summer 1999 - 50

tech EXPO
1999

- - DODECAHEDRONS
FOR PINOCClHO
- - - Greg Bell
Onerbein College

48

MMER

1999

The director and designer of an Otterbein College Theatre production of Pinocchio (by Arnold Wengrow,
music by 'icky Rea and Jackie Cassada), conceived of the playas if the action was presented by a bunch
of kids on a playground. The visual elements were greatly simplified, so the set consisted of oversize toy
blocks in various sizes, long poles and large fabric panels, which the cast stacked, draped and arranged
to create tlle different settings. However, the designer thought simply using cubes (regular six-sided
shapes) for tlle blocks would be boring, so she asked me if tlle shop could build them as dodecalledronshapes \vith twelve equal faces, each a regular pentagon. She wanted tlle blocks to be open, made from
some kind of tubing; in fact, her model piece was plastic straws hot-glued at the joints.
I quickly chose PVC pipe for the tubing, but had to cogitate a few days on a method for joining these
pipes togetller to make a dodecal1edron. 1\vo possible solutions emerged: some kind of exterior plate to
hold the pipes at the proper angles, or an interior fitting at each joint. As the designer preferred the look
of an interior fitting, the hardware I ultimately designed looked something like a Mercedes Benz hood
ornament laid flat on a table with each leg of the three-point star angled 18 degrees up from a common
plane. Since a dodecalledron has 20 joints and the designer specified seven of the shapes for the set, I
needed to fabricate 140 interior fittings to join tlle 30 pieces of PVC pipe needed for each unit. Given the
number of pieces, and since each fitting needed to be identical, it seemed best to cast each fitting from
some kind of resin poured into a mold. The total process would include: I) constructing a model fitting,
2) pouring a negative mold for the process, 3) casting the fittings, and 4) assembling and finishing the
dodecalledrons.
I fabricated the model fitting from the sanle type of casting resin I would use for the actual pieces.
After research into several different types of resins, I chose a two-part (A and B) urethane resin because
the technical data indicated that the material has a flexural strength and hardness rating rugged enough
for the job. More important though, this type of resin has a de-mold time of only two to six hours at 73 0 F,
and \vith 140 fittings to cast, a relatively short de-mold time was essential. I started by building a three-dimensional jig that held three 2-inch long pieces of I-inch diameter PVC pipe at the proper angles with
their outside edges all touching at a single central point. (See figure I.) Supporting blocks hot-glued to
the pipe pieces provided the external support needed to keep them 120 degrees apart (remember the
Mercedes hood ornanlent) and 18 degrees up from tlle plane of the table. Modeling clay shaped around
the central space where the PVC pipes met and gaffers tape placed over the open ends of the pipes enclosed the shape to be cast. (See figure 2.) The model mold was placed on the work table with tlle ends
of tlle pipe pieces down before spraying silicone lubricant on the modeling clay and into tlle pipe pieces
as a release agent. After hand mixing the urethane resin according to the manufacturer's directions it was
poured into the model mold through a clay danl built up at the central joint and completely filling that
space and each pipe piece. Once tlle resin cured (about 48 hours), the PVC pipe pieces, supporting
blocks and modeling clay were removed. With a bit of sanding and Dremel
tool finishing, the model was complete
and ready for the mold building process.
A mold for a fully dimensional
model (i.e. a model \vithout a flat side)
is usually built \vith two parts that are
placed together and secured. The casting material is then poured into the
mold through an opening in the mold
called a sprue hole. After the casting
hardens the two parts are separated to
allow removal of the finjshed piece. To
build the two-part mold for the dodecahedron fitting, I had to cast a negative
mold from the positive model fitting. I chose a silicone RTV (room temperature vulcanizing) rubber for
the mold material. It is very durable with a high tear strength and a heat resistance rating up to 400 0 F.
Silicone RTV rubber is sold in a two-part kit, usually mixed 10 parts of the rubber base to I part of the
catalyst (hardener) agent. It is available in many different viscosity and stiffness ratings, and I picked one
of the stiffest because I) the mold needed to maintajn the shape of the model fitting without any other
TD&T



Table of Contents for the Digital Edition of Theatre Design & Technology - Summer 1999

Contents
Theatre Design & Technology - Summer 1999 - 1
Theatre Design & Technology - Summer 1999 - 2
Theatre Design & Technology - Summer 1999 - 3
Theatre Design & Technology - Summer 1999 - Contents
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