Concrete Wall Tile Art

This project brings the elegance of traditional Indian Mehendi Patterns to life with Concrete Wall Tiles, perfect for creating unique art walls. Inspired by the intricate designs typically drawn on hands during gatherings and festivals, each tile measures 100 x 100 mm and connects seamlessly with others to form repeating patterns. By using a 3D-printed mold, you can create these tiles easily and customize wall art that combines culture with modern style.

List any tools or materials used.

1. 3D Printer: For printing the mold.
2. 3D Printing Filament: PLA or ABS filament to print the mold.
3. Autodesk Inventor: For designing the tile mold.
4. Concrete Mix: Any quick-setting concrete mix suitable for home decor projects.
5. Mixing Bowl: To mix the concrete.
6. Water: For mixing the concrete.
7. Spatula or Mixing Tool: To stir the concrete.
8. Sandpaper: For smoothing out any rough edges on the concrete tiles after they’re cured.
9. Optional Finishing Supplies: Paint, sealer, or colored pigments to customize the tiles if desired.

Open Autodesk Inventor and create a new part file. Start by drawing a 100 x 100 mm square as the tile’s main outline.

Divide this square into four equal sections using construction lines. These sections will act as guides to create patterns within each part of the tile.

Add Pattern Elements: Inspired by mehendi, sketch intricate floral or geometric designs within each quadrant. These designs should seamlessly connect at the edges so that the tile aligns smoothly with other tiles.

Extrude the Design: Select the patterns and use the extrusion tool to add depth. Aim for a depth of 2-3 mm for the designs, creating shallow but noticeable textures.

Create Mold Parts: To make the two-part mold, create a base plate for the pattern design and a second piece for the side walls. The side walls should be tall enough to create a mold cavity for a 100 x 100 x 10 mm concrete tile.

Export the Design: Save the completed mold design as an STL file, compatible with most slicer software.

Prepare for Printing: Open the STL file in your preferred slicer software. Adjust the print settings based on your filament type (PLA or ABS). A layer height of 0.2 mm is recommended for good detail, and infill density should be around 20-30% for strength.

Print the Mold: Start printing both parts (base plate and side walls). Each piece may take several hours to print depending on your printer’s speed.

Post-Processing: Once printed, sand any rough or uneven areas, especially inside the mold where the concrete will be poured, to ensure a smooth finish. Apply a coat of mold release spray to make demolding easier.

Mix Concrete: In a mixing bowl, combine the concrete mix and water per the package instructions. Slowly add water and mix until you reach a thick, smooth consistency (like peanut butter).

Optional Additives: If desired, add a bonding agent or pigment to the mix for extra strength or color.

Rest the Mix: Allow the mix to sit for a few minutes, helping any air bubbles rise to the surface.

Place Mold on a Flat Surface: Ensure your mold is on a flat and stable surface to prevent shifting while the concrete sets.

Fill the Mold: Pour or scoop the concrete into the mold, filling it to the top edge.

Level and Remove Bubbles: Use a spatula to spread the concrete evenly and tap the sides of the mold gently to release trapped air bubbles. Smooth the top with the spatula for a flat, clean finish.

Optional Texture: For added visual interest, lightly press a textured surface over the concrete’s top before it sets.

Initial Curing: Cover the mold with plastic wrap to retain moisture, which helps prevent cracks. Let the concrete set for at least 24 hours.

Final Curing: After 24 hours, carefully check the surface. If it’s firm, remove the plastic wrap and let it cure for an additional 24-48 hours for full strength.

Separate Mold Pieces: Carefully disassemble the mold by separating the side walls from the base plate.

Remove the Tile: Gently lift the tile out. If it’s stuck, gently tap the sides or use a small tool to help release it. Take care not to damage the tile.

Sand the Edges: Use fine-grit sandpaper to smooth any sharp or rough edges. This also helps tiles fit snugly when placed together.

Seal the Tile: If you’re using the tiles in a damp area, apply a concrete sealer for added durability.

Color or Paint: You can add colored pigments to bring out the patterns or paint the raised areas for contrast. Allow paint or sealant to dry completely before installing.

Arrange the Pattern: Plan your layout by arranging the tiles on a flat surface first. Experiment with different alignments to create your ideal pattern.

Mount the Tiles: Use a strong adhesive suitable for concrete to attach the tiles to the wall. Press firmly and hold for a few seconds to ensure they adhere well.

Finish the Installation: Once all tiles are in place, clean up any adhesive that may have seeped out from the edges. Allow the adhesive to cure as per the manufacturer’s instructions.