Archive for resin

Mold Making

Posted in DIY, Electronics Projects, molds with tags , , , , , on June 9, 2012 by Nilsen

After the “pain” I had when creating the wonderfully clear and smooth finish, the crazy sanding with 60 grit belt sander, then 200, then 600 water paper then 1200 water paper then hours of polishing it just was not feasible to make these things more often but since I had a shape I wanted I ordered some mold making silicone.

It comes in a tin with a catalyst which you obviously mix together, stir vigorously and pour around your item which you have encased in some sort of box.This produces a negative of the item which you can then easily use to replicate as you just pour in your resin and it does not stick to the mold. Brilliant.

I used some acrylic and a hot glue gun to quickly make this box.

Acrylic is perfect as it’s non porous meaning the silicone mold will easily pop right out when I remove the walls.

Box with device hotglued into it.

 

Unfortunately as can be seen in the first picture, when mixing the silicone many bubbles are introduced through the process of stirring so to remove them I could use a vacuum pump but I don’t have one so I found the “bombs away” method on Youtube. This method relies on the fact that the silicone is so viscous that if you let it stretch thin enough no bubbles can survive the thin end of the stretch. Maybe better explained in the below pictures.

Here my silicone in a cup with a hole made in the bottom covered with sticky tape.

Look at it go!

 

Here you see the silicone stretched extremely thin by gravity and the viscosity of the liquid

 

Make sure to land next to the object, not on it else you could introduce more bubbles, let the liquid flow over the object from the bottom of the mold box.

 

Nearly done.

 

The bottom of the mold box.

 

Here the completed thing.

 

Completed.

 

Now I will add another completed circuit and pour in some resin. Lets see.

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I have clarity now

Posted in DIY, Electronics Projects with tags , , , on May 30, 2012 by Nilsen

As previously mentioned, I ย ordered a polish from the supplier of the Resin as well as another type which is a special plastic polish used to fix scratches in phone displays etc.

Both work very well although I think the plastic polish is even better for the glass like finish.

Here some pics of the results:

This is the first of the special projects, more of a prototype I have to admit.

Unpolished and polished sides

 

Top View of the finished product

 

I am a little bit disappointed with the result as some resin leaked into the jack while I was sealing it, of all things… I had to drill it out, this caused damage to it so now I have a semi-working plug, you live and learn, I now use clear epoxy to seal the plugs.

 

It’s not completely polished yet, I need a dremmel )

 

Pretty Clear!

 

New Version, this one is customer ready, well besides not being polished ๐Ÿ™‚

 

Secret awesomeness

 

 

More to come…

Results!

Posted in DIY, Electronics Projects with tags , , , , on May 19, 2012 by Nilsen

Here they are! The cast products.

Firstly I am a little disappointed that I have not yet been able to buff the initial test cast to a clear glass like finish. It just won’t buff up even though it is so smooth now and I have tried various polishing compounds including a brasso equivalent (or maybe not) and a metal polish for chrome.

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Orange tinge is due to the cardboard box leaking some colour

I sanded the piece with 600, 800 then 1200 water paper and subsequently started to polish it, unfortunately it is not reacting the way I had hoped. I even attached a polishing wheel to my drill press but even that only left the resin dull. I know it is crystal clear as before I sanded the top it was like water.

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Another View

Here the trigger before sanding the cardboard mold away.

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In it’s little conffin.

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Coffin Removed!

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With backlight, my work needs a little work ๐Ÿ™‚

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Bottom

And here some other projects I have on the go, please welcome the Nilsen Slider – Control box.

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Controller being assembled.

More to come in a separate post.

Water Resin!

Posted in DIY, Electronics Projects with tags , , on May 14, 2012 by Nilsen

Firstly my previous breadboard of spaghetti has been “steampunked” if that makes any sense, I wanted it to look completely authentic when I cast it in the resin, luckily it works!

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Closeup view

And from afar

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The resin I purchased from Swiss Composites is a “Wasser Klar” resin which directly translated means “Water Clear”. It has the consistency of thick sugar water, or maybe a little thicker and it mixes beautifully, it is a pleasure to work with, even the smell is quite mild.

I created the mold with cardboard and mixed some resin to close the backs of plugs and tried to close the pot, unfortunately I have no idea if the pot will leak and it will break everything, that would be quite terrible. The circuit took a surprising time to make ๐Ÿ˜ฆ

I also mixed the resin with the suggested quantities, now we will see if it cures clear and with no cracks, it only raised about 4 degrees in temperature after setting into the mold.

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Looking forward to tomorrow, lets see how it turns out.

*Update*

After 10 hours the resin barely started to jellify, it sure does take a while to cure.

Will check again this evening.

**Update 2**

After 28 or so hours the resin has seemingly hardened but is still slightly tacky.

It also show that it is not set as the temp is a degree higher than ambient.

Resin Temp

Ambient.

Results with Resin

Posted in Electronics Projects with tags , , , , on May 10, 2012 by Nilsen

A quick update on the test with resin:

Notes, this is polyester resin, not epoxy resin, thus it is hardly useful for presentation purposes unless you want to drop in an insect and fake a fossil, nevertheless here are the results of my casting attempt.

I cast my 555 flashing LED timer into the “Amber” aaaaaaaand… it cracked due to too much catalyst. I have not seen catalyst like this, it’s a sort of paste so measuring 2-4% by volume is near impossible.

Here’s a picture to show the little waste of time.

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Here some components which weathered the storm of cracks…

The crack on the LED and some resistors, amazingly they survived.

Here’s a pic of my top secret project!

This is the circuit (properly made of course) to go into the clear resin, notice the simple components…

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More to come soon…

A test with resin

Posted in Electronics Projects with tags , , , , on May 6, 2012 by Nilsen

I had a lazy Sunday ahead and this was the perfect opportunity to try my hand at resin casting, especially casting electronics into resin.
The only resin I found was at a local hardware store and it looks like amber…
To be honest this whole thing started with blog I saw about a pre-amp which was cast in a clear resin cast and it looks absolutely amazing.
I have a lot of projects which I want to make and sell and I think this kind presentation sets it apart from the rest.
Here’s a link to the site:
http://runawaybrainz.blogspot.com/2012/04/audio-crystal-cmoy-freeform-headphone.html

I wanted to build a simple project which could benefit from the resin casting but also as a proof of concept for casting electronics into resin. I built a freeform 555 timer circuit which flashes a red and green LED, I used a circuit off a google search but didn’t have a 1uF cap, I used a 10uF instead so it switches every 7 seconds.

It is powered off USB so it can be one of those useless PC peripherals ๐Ÿ™‚

I will create a new one and cast in clear resin once I get it but I will also post the details of how it goes!

Here some details of 555 timer circuits, just added another LED to the positive rail to pin 3.

http://bit.ly/JfOrx2

Anyway its a start, I have subsequently ordered some clear resin, pics of the project coming soon.