Domo Caps [working thread]

[domoaligato]

mold max 25
https://www.farwestmaterials.com/component/virtuemart/mold-making-materials/mold-max-25-detail?Itemid=0

Crystal Clear 200
https://www.farwestmaterials.com/component/virtuemart/casting-materials/crystal-clear-200-detail?Itemid=0

So-Strong Tints
https://www.farwestmaterials.com/component/virtuemart/casting-materials/so-strong-tints-detail?Itemid=0

Ease Release 200
https://www.farwestmaterials.com/component/virtuemart/sealers-release-agents/ease-release-200-detail?Itemid=0

next to order:
vacuum chamber to de gas the materials prior to molding/casting
http://www.ebay.com/itm/1-5-Gallon-Vacuum-Chamber-and-CFM-Single-Stage-Pump-Degassing-Silicone-/321170742677?pt=BI_Pumps&hash=item4ac7449d95

Pressure pot.
http://www.artmolds.com/pressure-pot.html#

cheap air compressor for the pressure pot.
http://www.harborfreight.com/2-hp-8-gallon-125-psi-portable-air-compressor-67501.html

[domoaligato]

youtube resources that explain the process very well

Introduction to clear casting resin

How to use clear casting resin for encapsulations and casting

How to de gas silicone

Pressure casting resin

the entire smooth-on channel
https://www.youtube.com/user/SmoothOnInc/videos

smooth-on degassing

[domoaligato]

reserved

[SpAmRaY]

strong tints made me look twice....

and I was expecting to see one of these 



but looking forward to see what awesome keyboard science will happen here 

[CPTBadAss]

SO glad I didn't post as soon as I saw this so you could get your reserved threads. What designs are you looking to make?

I'm really excited for this project and all the new DIY cap projects ^__^

[domoaligato]

I have removed the head from this tf2 pyro figure and epoxied a cherry stem to the area where the neck would be.

[SpAmRaY]

I have removed the head from this tf2 pyro figure and epoxied a cherry stem to the area where the neck would be.

Show Image

That is WICKED!!!! :eek:

[CPTBadAss]

That was my favorite character in TF2 ^__^

[domoaligato]

that picture does not show the detail that is actually on the model's head. there are little ribbed lines across the eyes and it looks really good.

I am not going to waste my materials without a vacuum chamber and pressure pot so it will be a little bit before I have a prototype to show, but I wanted to open this thread as a build log.

[Xenderwind]

Pyro was my favorite when i was into flipping tf2 unusuals.  I'm honestly kind of surprised that a vacuum chamber thing is that cheap, I would have assumed they were more expensive than that.  Can't wait to see the end results

[domoaligato]

strong tints is also used to mix into clear resin to tint/color the resin.
testers model paint can also be used.

edit: like this
http://www.testors.com/products/136838

[Binge]

Domo, I'm totally interested in the degass and pressure chamber.  How much is your hardware setup projected to cost?

So far I've been having a lot of luck with oomoo 30 silicon and 325 and 327 casting plastics, but getting rid of the small bubbles would be awesome.

[domoaligato]

the links above has the costs... totaling 554.98 (without shipping) with the air compressor for the pressure pot.
if you already have a air compressor then 434.99 (without shipping).

I did alot of research into if I should make my own or buy one pre-made.
I determined that it was cheaper to spend the $199.99 on the pre-made pressure pot then to make my own half assed one.

same goes for the vacuum chamber.

[domoaligato]

So far I've been having a lot of luck with oomoo 30 silicon and 325 and 327 casting plastics, but getting rid of the small bubbles would be awesome.

I emailed farwestmaterials (authorized smooth-on reseller) telling them what I wanted to do (great people!)

which mold making solution(s) would you suggest for keyboard key caps?
I would like a mold that will last a very long time.

I would also like to cast in clear resin with a pressure pot to remove the bubble.
I was thinking smooth-on clear but I am unsure about the different numbers on the solutions.

thank you

I would recommend either OOMOO 25 or Mold Max 25 because of their flexural properties.
 
As far as the casting materials, Smooth-On Crystal Clear plastic resin, the numbers go as follows:
Crystal Clear 200 can be used in castings that range from 1/2" up to a 3" thickness
 
I would take a look at the task series of urethane plastics they too might work for what you are trying accomplish.

I want to look at the task series but I think there website just went down lol.

[domoaligato]

I guess I can go to smooth-on for that until they fix the site.

http://www.smooth-on.com/Urethane-Plastic-a/c5_1120_1157/index.html

edit:
when I try solid's I think I will get some Task® 3
it is white instead of clear and is 80D hardness
also "Vacuum degassing is not necessary"

http://www.smooth-on.com/tb/files/TASK_2_3_TB.pdf


"For Best Results . . . Best results are obtained using a pressure casting technique. After
pouring the mixed compound, the entire casting assembly (mold, dam structure, etc.) is
placed in a pressure chamber and subjected to 60 PSI (4.2 kg/cm2) air pressure for the full
cure time of the material"

from everything I have seen they say to cast at 60 psi but 40 psi is sufficient and is the standard that all the pressure pots support.

[domoaligato]

oh and this will help some people that do not understand shore hardness
http://www.smooth-on.com/pdf/durometer_with_logo.pdf

[domoaligato]

This thread is a brain dump. please excuse the frequency of my posts in here as I am not bumping. it is just me posting new info and sharing as I see appropriate and answering questions.

[CPTBadAss]

Dude....Do you mind if I add that shore durometer hardness chart link to my o-ring review? So people can better understand what it is?

[domoaligato]

Dude....Do you mind if I add that shore durometer hardness chart link to my o-ring review? So people can better understand what it is?

go ahead!

[domoaligato]

i went home for lunch and my stuff arrived. farwestmaterials is located in walla walla, wa so my stuff arrived next day.

[domoaligato]

so-strong colors sampler pack
 

[Tarzan]

I got some nice powdered colors from Kremer Pigments, but still working on getting molds right before casting anything.  The pressure/vacuum pots look intriguing, I've seen folks online using paint pots for pressure vessels, but these seem to go for more than the pressure kettle versions.

Watching this thread with interest!

[MOZ]

Watched Hooked

[domoaligato]

I know some of you already now this so you can ignore this.

my notes for the process

Wear a mask/glasses/gloves for all of this!

mold making
1. create box for the mold to go in.
2. place item in the box using clay to separate/divide the mold in 2 in a spots that will be easy to divide later.
3. place items like marbles/bolts into the clay to create keys for the mold to fit together.
4. use ease release to prevent the mold from sticking to the box/item/clay
5. mix the mold materials
6. place the mixed mold materials into the vacuum chamber to de gas them. it basically boils the material to get the air bubbles out. this will result in a smoother finish in the mold. between 28-30 hg. safely release the air pressure so that it doesn't explode everywhere.
7. pour mold materials into the mold box at one corner until it is a appropriate level above the item.
8. tap the sides of the box to ensure the mold has reached all the areas of the item it is supposed to.
9. wait for the mold to cure.
10. remove the mold from the mold box being careful to not destroy the box.
11. flip the mold upside down so the clay is facing up.
12. carefully remove the clay from the mold. do not remove the item from the mold!
13. remove the marbles/bolts from the mold.
14. create a pour spout and as many air holes as needed with clay and put it in this side of the mold. you will end up with 2 pieces of extra material that you will have to trim off later so make sure they are in a area that is not noticeable or easy to sand/trim later.
15. follow steps 4,5,6,6,8,9 above to complete the second half of the mold.
16. gently separate the mold and use a exacto blade if needed to slice the halfs where the ease release did not prevent the mold pieces from sticking together.
17. remove the master item and clay pieces from the mold.

casting.
1. spray the mold pieces on the inside with ease release and brush in the pieces to ensure coverage.
2. use electrical tape to tape the two mold pieces together.
3. mix the casting materials and ALWAYS ADD COLOR TO PART B FIRST.
4. de gas the materials as stated above.
5. pour the casting material into the pour spout. you may need to tap the sides of the mold to ensure that the casting material has made it to every part of the inside of your mold.
6. place the mold box into the pressure pot and pressurize to 50 psi
7. let it cure overnight.
8. release the pressure from the pressure pot slowly and safely
9. carefully separate the mold and remove your new item.
10. trim any excess material from the item using a exacto blade and/or sand with a dremel tool.

[domoaligato]

Is this overkill?



http://www.amazon.com/Israeli-Civilian-Mask-Nato-Filter/dp/B0002XJ2OU/ref=sr_1_4?s=hi&ie=UTF8&qid=1375825070&sr=1-4

[vun]

Never overkill, protects both your eyes and lungs while making you look badass. Win win win situation.

[MOZ]

Is this overkill?

Show Image

http://www.amazon.com/Israeli-Civilian-Mask-Nato-Filter/dp/B0002XJ2OU/ref=sr_1_4?s=hi&ie=UTF8&qid=1375825070&sr=1-4

No!

[Binge]

So they recommend to degas the casting plastics?  Interesting

[domoaligato]

So they recommend to degas the casting plastics?  Interesting

edit: some say required and some say not required. but they all basically say for best results they recommend it.

[domoaligato]

i had to move the stem....

[bueller]

Interesting, I might have to look at converting a spray paint pressure pot for this! One of my mates is a master sculptor as well so he can probably help me knock together some awesome stuff.

[domoaligato]

Interesting, I might have to look at converting a spray paint pressure pot for this! One of my mates is a master sculptor as well so he can probably help me knock together some awesome stuff.

there is a few youtube videos with instructions already to do this.

and

and

[domoaligato]

I totally believe that if we are going to post in "making stuff together", we should be making stuff together.
I will be sharing as much info as I can.

[domoaligato]

this is a amazing series of videos.

this one is about pour spouts and mold boxes with legos

[bueller]

I totally believe that if we are going to post in "making stuff together", we should be making stuff together.
I will be sharing as much info as I can.

Good man

That's what I love about this place, I've only been a member since March but I've already had so much help from people. My friends and family think I'm insane but there's something pretty awesome about typing on something you've built with your own two hands

[domoaligato]

the more I watch the more I think I might skip the vacuum chamber and try without it.

edit: I am going to just get a pressure pot and see what happens.

[Tarzan]

Watched Hooked

Heh!  Indeed!

Yesterday I ordered 1-kilo kits of Quantum Silicones QM 262, and QM 270.  Looks like I'm started down another wallet-paining sidepath. 

 

[domoaligato]

I have ordered and received trial packages so that if I do not like a product I am not out to much money.

[Tarzan]

I was planning to order some Innovative Polymers IE-3075, or TP-4052 (high impact rating).  These are translucent, not water-clear, but I plan on coloring them anyway. 

Anyone have experience ordering from http://www.innovative-polymers.com?

[domoaligato]

I was planning to order some Innovative Polymers IE-3075, or TP-4052 (high impact rating).  These are translucent, not water-clear, but I plan on coloring them anyway. 

Anyone have experience ordering from http://www.innovative-polymers.com?

I would buy from smooth-on directly unless your looking for something that do not have.
they are in Easton, Pennsylvania so the shipping should be cheap and as a added bonus there products are $2.00 cheaper directly then farwestmaterials.com that I ordered from.

I ordered from farwestmaterials.com because they are instate and I received my stuff the next day.

[Tarzan]

I was planning to order some Innovative Polymers IE-3075, or TP-4052 (high impact rating).  These are translucent, not water-clear, but I plan on coloring them anyway. 

Anyone have experience ordering from http://www.innovative-polymers.com?

I would buy from smooth-on directly unless your looking for something that do not have.
they are in Easton, Pennsylvania so the shipping should be cheap and as a added bonus there products are $2.00 cheaper directly then farwestmaterials.com that I ordered from.

I ordered from farwestmaterials.com because they are instate and I received my stuff the next day.

Thanks for the tip!  I'm in Virginia, so shipping from Pennsylvania should be painless.

[Tarzan]

I checked out my local Harbor Freight store over lunch, and they have those 2.5 gallon pressurized paint pots in stock.  $100, or $75 if you spend $30 for a year's membership in their customer loyalty program.     Might be worth it if there was enough other stuff on sale to recoup the program cost.

Didn't buy the paint pot, still figuring out what all I want to invest in.  Plus, the thing was so shoddily built it was appalling; ports and bungs were welded at weird angles, gauge and regulator were loose in the pot; didn't inspire much confidence. 

Also checked out air compressors while I was there, and they do have some cheap ones ($60-$90), but I think I'll scrounge a name brand off of Craigslist instead.  The hunt continues...

[domoaligato]

that is why i linked that one for 199.99

by the time you add the parts to convert the harbor freight one you have spent 200 already.


edit: I guess it depends on the exact parts you get from harbor freight but I am going to get the 199.99 one as it looks like a little better quality.

[domoaligato]

stem attached to the master and modified to fit in any switch rotation.

[nubbinator]

Love it.  Wish it had the more traditional base, but looks awesome.

[MOZ]

Looks great! 

[domoaligato]

Love it.  Wish it had the more traditional base, but looks awesome.

this may be in a poll soon.

[MKULTRA]

Following this thread...  May we have learned the secrets of the Clack Factory gnomes?

[CPTBadAss]

Yo....that pyro head looks incredible. IT'S SO SMOOTH!

[domoaligato]

I am sure that experience is how you get to the level mister click clack is at.
I love his work and he has perfected his craft.