Key Points
- Why 6061–T6 aluminium, SS304 steel, and brass were combined to tune a kinetic training tool.
- How coatings, refractory panels, and ceramic surfaces manage heat, safety, and aesthetics in fireplaces.
- Where FEA, tight tolerances, and mixed manufacturing methods make the difference between “nice object” and long-life equipment.
Full interview with George Avgerinakis
1. Action Tube (2025) appears to reflect an industrial and perhaps kinetic character. Could you specify the key material(s) that define its structural or aesthetic identity, and why those were chosen?
The action tube, is a training tool based on kinetic dynamics that aims at controlled training through the displacement of the operator's balance. The material that was chosen for the production of this project was 6061-T6 extruded aluminum alloy, for the tube, since it has a great combination of low weight, durability & production. As for the inside motion part of ballast, a combination of SS304 & CC764S, a special brass rod for it’s great high density & length ratio.
2. What were the principal material challenges in Action Tube’s design, such as strength-to-weight ratio, thermal behaviour, or surface finish, and how did you address them in the development phase?
For action tube’s moving ballast part, it was crucial to address the maximum weighted part with a minimum length, in order to achieve optimized acceleration of the ballast when the operator changes the handling angle. Furthermore, it was significant for the finishing materials to perform the highest level of resistance to alkaline environments, which was achieved by using a special blend of coarse-textured pure polyester powder coating, in a variety of colors.
3. In Fireplaces & Stoves (2025), you’ve merged energy‑efficient heating with high‑end aesthetics. Could you describe how material selection played a role in balancing thermal performance with visual appeal and manufacturability?
In the field of energy-efficient fireplace production, there are not many options in manufacturing materials; usually, the RSt37-2 derivatives are the most common and efficient. In my design study for the fireplace and stove product range, however, we combined materials such as extruded steel profiles with sections of ceramic-coated metal surfaces and refractory panels.
The decision to use these innovative materials, as well as a blend of special high thermal grade paint finishes, through a joint-free design, resulted in remarkable aesthetic products with excellent heating performance.
4. For Action Tube, how did your design approach pivot between styling and engineering. Did technical constraints such as tolerance, heat dissipation, or mechanical actuation influence material choices?
The design approach was driven by the principles of applying basic geometric shapes and optimal instrument function. Clear shapes reduce production complexity and achieve an evident functional way to engage with the product.
The biggest constraint on the final implementation of designing the action tube, was the dimensional requirements and tight tolerances of the components produced. Due to the ergonomic nature of the instrument, the dimensions of the components had to be as precise as possible in order to reduce failures and material fatigue, as well as to ensure the functional integrity of the product over time.
5. When designing heating equipment like Fireplaces & Stoves, what material-led strategies did you implement to control heat retention, safety (e.g., surface temperature), and long-term durability across production batches?
During the design process, FEA simulations and extensive analysis were performed to extract data on areas that needed attention for maximum structural and thermal performance. These areas were carefully tested and redesigned using a range of materials, such as refractory panels with varying chemical densities, until high thermal insulation and product safety were achieved and approved for mass production.
6. Can you describe any specialized manufacturing or processing techniques, such as CAD-driven casting methods, post‑machining, or surface treatments, that were essential for achieving the refined finishes or tolerances in Action Tube or Fireplaces & Stoves?
Both traditional and modern manufacturing techniques were used for action tube & Fireplaces projects, such as sheet metal forming, steel bending, punching, as well as specialized methods such as cold rolling, profile extrusion, CNC milling, and EDM. During the design process, multiple prototypes were created for testing and evaluation using SLS, FDM, and Poly-Jet 3D printing techniques.
