Hot Wire Extensions presents adaptable, sustainably conscious design pieces and commissions. Led by Fabio Hendry, Hot Wire Extensions fosters material innovation and experimental engineering, which has led to the innovative manufacturing process.

The process was developed as a response to changing material landscapes, critically analysing and questioning the consequences of technical innovation. Hot Wire Extensions designs and develops a diverse range of products, furniture and installations as well as bespoke commissions, all characterised by the dedication to the mindful exploration of material landscapes. Pieces are recognised by their organic bone-like structures inspired by nature and geometry.

Fabio Hendry is a designer whose work seeks to explore new potentials for overlooked matter, from architectural systems to materials. Hendry is interested in exploring disruptive approaches to industrial manufacturing, revealing alternative systems of production. It is his belief that design practices and ecological theories can be merged to allow us to critically consider our material landscape. Hendry is interested in the analysis of innovative and future industries and takes inspiration from nature’s ability to adapt and reconstruct. His innovative products and hands-on experiments explore the boundaries between crafts and industry.

Due to the surge of innovation in 3D printing technologies, SLS printing has become popular because of its design freedom, high productivity and relatively low cost. However, the nature of the printing process means that large quantities of SLS nylon powder is left as by product, leading to unforeseen wastage whose disposal has not been considered. The Hot Wire Extensions process fuses nature and innovation by taking inspiration from the way a vine grows around a tree and developing a process that repurposes waste nylon powder. A nichrome wire is shaped and placed within a container filled with nylon powder and silica sand. An electric current is sent through the wire, causing the mixture to solidify around the form leading to endless possibilities in shape, scale and possible application. The process seamlessly binds materials, turning transient lines into durable, organic and bone-like structures.