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geekhack Projects => Making Stuff Together! => Topic started by: wtfridge on Thu, 14 February 2019, 12:05:40

Title: zZzCaps : My first foray into capmaking
Post by: wtfridge on Thu, 14 February 2019, 12:05:40
Hey peeps, I'm wtfridge and I'm pretty new around here.

I feel in love with mechanical keebs around 2013–my first was a Razer Blackwidow with MX blues, but I didn't really get into the hobby until last August. It's been a wild ride ever since, and even more recently I'm really getting into artisans.

So here we are today. I want to break into the ever-growing artisan-crafting scene with some of my own designs, and I've got one today to show you all...

Presenting... The Shambler.

[attach=1]

It's modeled after one of my favorite monsters, The Shambler (https://darkestdungeon.gamepedia.com/Shambler), from one of my favorite games of all time, Darkest Dungeon (https://www.darkestdungeon.com/). Being one of the most incomprehensibly harrowing eldritch horrors, I wanted to attempt to capture it's likeness so that it can start haunting your boards.

The pictures shown are probably my fourth or fifth attempt at the sculpt (I'll post those embarrassing first attempts later maybe), and I'm pretty proud of how it came out. I made it using beige-colored Super Sculpey, modeled on top of a $ynth v3.0 by HWS/Salvun. I've still got some finishing touches to make, but this is 99% done, I'd say. All that's left to do is start attempts at making the silicone mold and then the fun part of casting it and experimenting with colors and such.

I'm pretty scared of the next step, involving creating the mold. You can see in the pictures below that the top row of teeth have empty space behind them, so when making the silicone mold and removing it, it will probably break the teeth. I can probably add some clay behind the teeth, but it just won't look as "realistic". But I guess that's not too big a deal. Any advice/input here would be cool :).

I've got some other questions regarding mold-making/casting as well. Now I've tried my best to do pretty extensive research, looking through similar posts like mine made by those that are renowned in this community (Booper, ETF, what have you) and I'm still a little unsure on one thing and that's the question of vacuum degassing vs pressure chambers. I've seen that people use vacuum degassing for the mold-making process, and pressure casting for the actual resin-casting process. That's pretty expensive for someone starting out like me, so I was curious whether one of these tools will do a good job of both mold-making and resin-casting?

Also, if y'all have got any good recommendations on these tools, that'd be swell. I'd feel more comfortable knowing you more experienced folk have tested and can vouch for the vacuum/pressure chambers suggested.

Anyways, sorry for the wall of text. I'll be updating this post with progress and replies in the days to come. Hopefully the day that I come back here with some actual caps to offer and show off is not far off.

Later, friends. :)

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Title: Re: zZzCaps : My first foray into capmaking
Post by: gr4v3m4n on Sat, 16 February 2019, 19:47:16
Hei, if you willing to consider getting out of the synth system or hanging out with bunch of talented artisan sharing tips and tricks about casting, sculpting or just about anything you can think of. why dont you try joining https://discord.gg/nUsyadp

Sent from my SM-G935F using Tapatalk

Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Sat, 16 February 2019, 21:10:35
Hei, if you willing to consider getting out of the synth system or hanging out with bunch of talented artisan sharing tips and tricks about casting, sculpting or just about anything you can think of. why dont you try joining https://discord.gg/nUsyadp

I think the Synth and ZButt are about the same "quality" when it comes to internals design. And the synth doesn't have print lines.
Title: Re: zZzCaps : My first foray into capmaking
Post by: dustinhxc on Sat, 16 February 2019, 21:27:39
Hey that’s a really cool design man. Love the teeth! You have some good sculpting abilities. Look forward to seeing your progress.
Title: Re: zZzCaps : My first foray into capmaking
Post by: gr4v3m4n on Sat, 16 February 2019, 21:35:12
Hei, if you willing to consider getting out of the synth system or hanging out with bunch of talented artisan sharing tips and tricks about casting, sculpting or just about anything you can think of. why dont you try joining https://discord.gg/nUsyadp

I think the Synth and ZButt are about the same "quality" when it comes to internals design. And the synth doesn't have print lines.
Im not trying to discourge the synth or anything, just giving another cheaper option i can even say that the butt for synth that theglyph made also can be a cheaper option...

Sent from my SM-G935F using Tapatalk

Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Sat, 16 February 2019, 21:35:58
I've got some other questions regarding mold-making/casting as well. Now I've tried my best to do pretty extensive research, looking through similar posts like mine made by those that are renowned in this community (Booper, ETF, what have you) and I'm still a little unsure on one thing and that's the question of vacuum degassing vs pressure chambers. I've seen that people use vacuum degassing for the mold-making process, and pressure casting for the actual resin-casting process. That's pretty expensive for someone starting out like me, so I was curious whether one of these tools will do a good job of both mold-making and resin-casting?

You 100% need a pressure chamber for casting. You should make your molds under pressure since you will be using them under pressure when you have resin in them (or else they may deform). Some silicones require vacuum degassing, but not all, so you can certainly get by without a vacuum chamber.

You can start without casting under pressure, but you'll have bubbles in your casts and wouldn't have the quality required to sell your caps.

$400ish is certainly a good chunk of change, but it's a one time cost up front (for the pot and the air compressor) and is a requirement of artisan cap making.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Sat, 16 February 2019, 23:19:59
Hei, if you willing to consider getting out of the synth system or hanging out with bunch of talented artisan sharing tips and tricks about casting, sculpting or just about anything you can think of. why dont you try joining https://discord.gg/nUsyadp

Sent from my SM-G935F using Tapatalk



Hey man, that'd be great! I'll be sure to check out the Discord you linked, I'd love to get more involved with a like-minded community. As for the $ynth, I opted to get this after doing a lot of research cause it just really seemed to be a well-machined piece of equipment built-to-last. I've seen other systems that are open-sourced and WAY cheaper, but in the end I decided to shell a little cash for the $ynth and am loving it.

I'm sure other systems are just as fine, but I personally opted for this one. :)
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Sat, 16 February 2019, 23:22:04
Hey that’s a really cool design man. Love the teeth! You have some good sculpting abilities. Look forward to seeing your progress.

Thanks very much for the kind words! Means a lot for a rookie like me. I've gone out and bought some more supplies today and hopefully will try to do some preliminary casts tomorrow and will update this post.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Sat, 16 February 2019, 23:25:38
I've got some other questions regarding mold-making/casting as well. Now I've tried my best to do pretty extensive research, looking through similar posts like mine made by those that are renowned in this community (Booper, ETF, what have you) and I'm still a little unsure on one thing and that's the question of vacuum degassing vs pressure chambers. I've seen that people use vacuum degassing for the mold-making process, and pressure casting for the actual resin-casting process. That's pretty expensive for someone starting out like me, so I was curious whether one of these tools will do a good job of both mold-making and resin-casting?

You 100% need a pressure chamber for casting. You should make your molds under pressure since you will be using them under pressure when you have resin in them (or else they may deform). Some silicones require vacuum degassing, but not all, so you can certainly get by without a vacuum chamber.

You can start without casting under pressure, but you'll have bubbles in your casts and wouldn't have the quality required to sell your caps.

$400ish is certainly a good chunk of change, but it's a one time cost up front (for the pot and the air compressor) and is a requirement of artisan cap making.

Gotcha, thanks very much for the info. I did more research and I definitely don't want to cheap out on the pressure chamber (esp after reading horror stories about cheaper quality ones).

I've seen that Smooth-On sells one for around $800 and I've also seen that Binks is a very reliable manufacturer/distributor of a pressure chamber. Was wondering where I could get one for around $400 like you mentioned and how that ones compares in quality to, say, the $800 one I mentioned here (https://shop.smooth-on.com/pressure-pot).

And I'll do more research about whether or not I will need a degasser. I currently have Oomoo 30 for my silicone formula. Was also thinking of picking up MoldStar 30 as that seems to cure much harder and that might be good.
Title: Re: zZzCaps : My first foray into capmaking
Post by: gr4v3m4n on Sat, 16 February 2019, 23:35:44


Hei, if you willing to consider getting out of the synth system or hanging out with bunch of talented artisan sharing tips and tricks about casting, sculpting or just about anything you can think of. why dont you try joining https://discord.gg/nUsyadp

Sent from my SM-G935F using Tapatalk



Hey man, that'd be great! I'll be sure to check out the Discord you linked, I'd love to get more involved with a like-minded community. As for the $ynth, I opted to get this after doing a lot of research cause it just really seemed to be a well-machined piece of equipment built-to-last. I've seen other systems that are open-sourced and WAY cheaper, but in the end I decided to shell a little cash for the $ynth and am loving it.

I'm sure other systems are just as fine, but I personally opted for this one. :)

Its cool, come hangout than..

Sent from my SM-G935F using Tapatalk

Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Sun, 17 February 2019, 10:14:00
I've got some other questions regarding mold-making/casting as well. Now I've tried my best to do pretty extensive research, looking through similar posts like mine made by those that are renowned in this community (Booper, ETF, what have you) and I'm still a little unsure on one thing and that's the question of vacuum degassing vs pressure chambers. I've seen that people use vacuum degassing for the mold-making process, and pressure casting for the actual resin-casting process. That's pretty expensive for someone starting out like me, so I was curious whether one of these tools will do a good job of both mold-making and resin-casting?

You 100% need a pressure chamber for casting. You should make your molds under pressure since you will be using them under pressure when you have resin in them (or else they may deform). Some silicones require vacuum degassing, but not all, so you can certainly get by without a vacuum chamber.

You can start without casting under pressure, but you'll have bubbles in your casts and wouldn't have the quality required to sell your caps.

$400ish is certainly a good chunk of change, but it's a one time cost up front (for the pot and the air compressor) and is a requirement of artisan cap making.

Gotcha, thanks very much for the info. I did more research and I definitely don't want to cheap out on the pressure chamber (esp after reading horror stories about cheaper quality ones).

I've seen that Smooth-On sells one for around $800 and I've also seen that Binks is a very reliable manufacturer/distributor of a pressure chamber. Was wondering where I could get one for around $400 like you mentioned and how that ones compares in quality to, say, the $800 one I mentioned here (https://shop.smooth-on.com/pressure-pot).

And I'll do more research about whether or not I will need a degasser. I currently have Oomoo 30 for my silicone formula. Was also thinking of picking up MoldStar 30 as that seems to cure much harder and that might be good.

A lot of people use the CA Tech 2.5gal tank which is currently just under $350. Then you just need an air compressor. Here's a link:
https://www.finishsystems.com/collections/resin-mold-casting/pressure-tanks

Many (all?) Binks pots are ASME certified, so they cost more. There have been no reported issues with CA Tech pots in our community (where as the super cheap Harbor Freight pots are known to have lid failures). The CA Tech pot is very solid and you won't be disappointed with it.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Sun, 17 February 2019, 23:38:14
I've got some other questions regarding mold-making/casting as well. Now I've tried my best to do pretty extensive research, looking through similar posts like mine made by those that are renowned in this community (Booper, ETF, what have you) and I'm still a little unsure on one thing and that's the question of vacuum degassing vs pressure chambers. I've seen that people use vacuum degassing for the mold-making process, and pressure casting for the actual resin-casting process. That's pretty expensive for someone starting out like me, so I was curious whether one of these tools will do a good job of both mold-making and resin-casting?

You 100% need a pressure chamber for casting. You should make your molds under pressure since you will be using them under pressure when you have resin in them (or else they may deform). Some silicones require vacuum degassing, but not all, so you can certainly get by without a vacuum chamber.

You can start without casting under pressure, but you'll have bubbles in your casts and wouldn't have the quality required to sell your caps.

$400ish is certainly a good chunk of change, but it's a one time cost up front (for the pot and the air compressor) and is a requirement of artisan cap making.

Gotcha, thanks very much for the info. I did more research and I definitely don't want to cheap out on the pressure chamber (esp after reading horror stories about cheaper quality ones).

I've seen that Smooth-On sells one for around $800 and I've also seen that Binks is a very reliable manufacturer/distributor of a pressure chamber. Was wondering where I could get one for around $400 like you mentioned and how that ones compares in quality to, say, the $800 one I mentioned here (https://shop.smooth-on.com/pressure-pot).

And I'll do more research about whether or not I will need a degasser. I currently have Oomoo 30 for my silicone formula. Was also thinking of picking up MoldStar 30 as that seems to cure much harder and that might be good.

A lot of people use the CA Tech 2.5gal tank which is currently just under $350. Then you just need an air compressor. Here's a link:
https://www.finishsystems.com/collections/resin-mold-casting/pressure-tanks

Many (all?) Binks pots are ASME certified, so they cost more. There have been no reported issues with CA Tech pots in our community (where as the super cheap Harbor Freight pots are known to have lid failures). The CA Tech pot is very solid and you won't be disappointed with it.

Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.
Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Mon, 18 February 2019, 00:39:44
Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.

Honestly, any air compressor that can hit 60-80PSI will do. My only recommendation would be to look at the dB rating and buy the QUIETEST one you can.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Mon, 18 February 2019, 02:06:18
Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.

Honestly, any air compressor that can hit 60-80PSI will do. My only recommendation would be to look at the dB rating and buy the QUIETEST one you can.

Noted. I shall do more research tomorrow. In the meantime, will probably order that CA Tech pressure pot. Thanks very much for all the advice!
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Mon, 18 February 2019, 20:26:45
Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.

Honestly, any air compressor that can hit 60-80PSI will do. My only recommendation would be to look at the dB rating and buy the QUIETEST one you can.

Did some looking around and this one seems to be one of the quietest I could find, and it looks to be a pretty decent price. You think this one (https://www.amazon.com/California-Air-Tools-CAT-1P1060SP-Compressor/dp/B077CNLPBC/ref=sr_1_10?s=hi&ie=UTF8&qid=1550542130&sr=1-10&keywords=California+air+tools+compressor#customerReviews) would be good?
Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Mon, 18 February 2019, 20:51:57
Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.

Honestly, any air compressor that can hit 60-80PSI will do. My only recommendation would be to look at the dB rating and buy the QUIETEST one you can.

Did some looking around and this one seems to be one of the quietest I could find, and it looks to be a pretty decent price. You think this one (https://www.amazon.com/California-Air-Tools-CAT-1P1060SP-Compressor/dp/B077CNLPBC/ref=sr_1_10?s=hi&ie=UTF8&qid=1550542130&sr=1-10&keywords=California+air+tools+compressor#customerReviews) would be good?

Yeah, that's going to be about as loud as a conversation in a public place, so not bad at all. (Reference: http://www.industrialnoisecontrol.com/comparative-noise-examples.htm)
Title: Re: zZzCaps : My first foray into capmaking
Post by: weaston on Mon, 18 February 2019, 21:02:24
This is so awesome, would love to get one.  The detail is crazy, way more advanced than any first time sculpter imo.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Mon, 18 February 2019, 23:33:00
Got it, thanks. I will look into getting that one you linked. Do you have any recommendations for an air compressor? I've heard that the quality of the compressor doesn't matter as much as it does for the pressure chamber.

Honestly, any air compressor that can hit 60-80PSI will do. My only recommendation would be to look at the dB rating and buy the QUIETEST one you can.

Did some looking around and this one seems to be one of the quietest I could find, and it looks to be a pretty decent price. You think this one (https://www.amazon.com/California-Air-Tools-CAT-1P1060SP-Compressor/dp/B077CNLPBC/ref=sr_1_10?s=hi&ie=UTF8&qid=1550542130&sr=1-10&keywords=California+air+tools+compressor#customerReviews) would be good?

Yeah, that's going to be about as loud as a conversation in a public place, so not bad at all. (Reference: http://www.industrialnoisecontrol.com/comparative-noise-examples.htm)

Oh cool, that's a handy comparison chart. Great, looks like I'm covered on a compressor and a pressure tank then.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Mon, 18 February 2019, 23:35:11
This is so awesome, would love to get one.  The detail is crazy, way more advanced than any first time sculpter imo.

Thanks for the kind words! The sculpt you see in the post took a ton of trial and error; the first iterations don't look NEARLY as good, hahaha. And I'd love for you to get your hands on one! I just need to order some more equipment and I can finally get casting. I baked the sculpt yesterday and it still retained all the details (I was super nervous that I'd have to start over if this step went wrong).

Super pumped for what's to come and to show everyone.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Tue, 05 March 2019, 23:19:25
Hey folks,

Been a while since my last update. :) This was because my girlfriend's parents came over to visit and stayed with us for a couple weeks so I couldn't find the time to sit down and make some progress. But they've since left and I've gotten straight to work.


!!!SPOILER!!!: There isn't much progress in this post, but I wanted to post anyway because I'm sure future capmakers can learn from the mistakes I made!


Anyways, the goal for this update was hopefully to have a finished silicone mold, but it is still in the solidification process as I type this. I got all my equipment over the past couple weeks, the notable pieces include:

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[attach=3]Excuse the jank setup, we're in the process of moving to a new apartment so I didn't want to set up the work-desk and everything just to move it again fully-assembled.
(The rest of my equipment)


1. Mold-making


I chose to go with Oomoo 30 (https://www.amazon.com/Smooth-Silicone-Making-OOMOO-30/dp/B004BNF3TK) for my silicone, but I did run into some issues (I think) with it. I had done some pretty extensive research before making purchases, and I had found that Oomoo 30 silicone was a perfectly good starter silicone, so I decided to go with it. I watched FiscalRascal's video on mold-making (https://www.youtube.com/watch?v=ZI_kP_8o2y0) a bunch, and I noticed a few things:

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[attach=5]
Okay, my turn!

Now, when I went ahead and started pouring my Oomoo, I noticed some things as well:

Suffice it to say, I was pretty puzzled and concerned at this point. But heck, I got this far, might as well mix it and not let it go to waste. So mix it, I did. It was pretty tough, with the Part A being so thick - my hand got pretty tired, not gonna lie. I powered through, transferring it to and from each cup (like in the video) and mixing away for a good 5 or so minutes. It was at this point I noticed that my mixture wasn't purple like in the video. It was more of a blue-ish color, very much like the Oomoo Part B was when it first started, but a little more purple, I guess.[/b]

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[attach=4]
Here's a pic of what I'm talkin' about.

Pretty concerning, but I charged on and went ahead and poured it into my $ynth mold. I'm pretty worried that I might have just ruined my sculpt, but we shall see tomorrow morning when it will be done setting (fingers crossed).


2. Pressurizing


Now it was time to go ahead and throw it in the expensive pressure pot setup I had purchased.

I had done the preliminary test run of the air compressor and everything looked good. I threw the mold in the pot, sealed it up, made sure all the valves were properly closed, connected the hose to both apparatuses and flipped the compressor on.

That's when I noticed another problem. The compressor wasn't filling up very quick, and when it was at around 90 psi I noticed it slowed down more and that there was a pretty loud hissing. The hissing was air escaping somewhere. I felt around with my hands and found the culprit to be the coupler I had installed onto the main air inlet on the pot. I flipped the compressor off, emptied the air, and tried tightening the couplet and tried again. Same result.

Pretty much gave up at this point and went back to doing research. Looks like I need some thread sealant, and I settled on buying Loctite 545 thread sealant (https://www.amazon.com/gp/product/B003XZB54O/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1) after reading its reviews and watching a video recommend it.



In conclusion,

that's pretty much where I am at this point. I'm pretty nervous about the sculpt and really hope it doesn't get ruined, cause I'll have to start over. Not the biggest deal I guess, but I was pretty proud of the sculpt and it would be tough to replicate it. I've ordered the thread sealant and will try this whole process again once I apply it (hopefully tomorrow after work), and I hope I will have a more fruitful update for y'all following that.

But that's it for me. Hope some people learn something from this update, sorry again that I don't have any solid results. Promise there will be next time!  ;)
Title: Re: zZzCaps : My first foray into capmaking
Post by: fufu279 on Wed, 06 March 2019, 00:57:12
Really nice sculpt. I had just started same time as you.
In my opinion, I suggest to use Mold Star 15 or 30 from Smooth On and also mold release.
With the pressure chamber, I am currently using TCP Global models and always stick with around 50-60 psi (it has enough pressure to kill all the bubbles)
And I also suggest having a vacuum chamber, which creates a lot of efficiency for silicone mold.
Cheer up  :thumb: :thumb:
 
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Wed, 06 March 2019, 13:30:43
Really nice sculpt. I had just started same time as you.
In my opinion, I suggest to use Mold Star 15 or 30 from Smooth On and also mold release.
With the pressure chamber, I am currently using TCP Global models and always stick with around 50-60 psi (it has enough pressure to kill all the bubbles)
And I also suggest having a vacuum chamber, which creates a lot of efficiency for silicone mold.
Cheer up  :thumb: :thumb:
 


Hey, thanks!

And yes, I've been meaning to pick up some Mold Star 30, I will try to do that probably this weekend. I use Mann 200 mold release and I think it's not too bad, but I've heard that the Smooth-on one is very good, so I might pick up some of that as well.

In regard to pressure chamber, I was planning to do around 60psi (until the air leak, haha). And I want to get a vacuum chamber eventually but I wanted to see how the pressure setup works first. How would the vacuum chamber make the mold-making process more efficient? Just curious. I thought that that would involve throwing the mold in BOTH the vacuum chamber AND the pressure pot. Wouldn't that take longer? Maybe I have the wrong idea.

But thanks! Good luck to you in your cap-making :)
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Wed, 06 March 2019, 13:42:52
Quick Update



I woke up this morning with a fever :( but I still wanted to check out the results of the mold, so I quickly opened up the pressure pot to check it out.

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It doesn't look too bad! There are bubbles, of course, but it doesn't look or feel too terrible. The sculpt was fine during and after removal of the mold, and the mold actually feels OK. A little too pliable, so maybe Mold Star 30 will be a more apt choice for silicone, but all in all, I'm not too upset with the results. With a working pressure setup, the mold would probably be great.

Sculpt pics

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The sculpt has some left over silicone in the tight crevices, but not too bad. The teeth (the part I was most worried about) are fully intact, and the little bits of silicone should be easy to remove with some precision tweezers. I'm debating whether or not I should make the second part of the mold (for the butt) and try actually casting some test caps with resin using this mold, but that brings up another issue--removing the sculpt from the $ynth, which I am preeeetty worried about.

The $ynth has the sculpt baked onto it, and I'm not too sure how I should approach removing it, all while minimizing damage to the integrity of the sculpt itself. I will probably try using an X-Acto blade to try to slice the base of the sculpt off of the $ynth, I dunno, I'll do some more research before attempting this.

But yeah, that's it for this quick update. Excited for what's to come  :D :D
Title: Re: zZzCaps : My first foray into capmaking
Post by: fufu279 on Wed, 06 March 2019, 20:40:11
Really nice sculpt. I had just started same time as you.
In my opinion, I suggest to use Mold Star 15 or 30 from Smooth On and also mold release.
With the pressure chamber, I am currently using TCP Global models and always stick with around 50-60 psi (it has enough pressure to kill all the bubbles)
And I also suggest having a vacuum chamber, which creates a lot of efficiency for silicone mold.
Cheer up  :thumb: :thumb:
 


Hey, thanks!

And yes, I've been meaning to pick up some Mold Star 30, I will try to do that probably this weekend. I use Mann 200 mold release and I think it's not too bad, but I've heard that the Smooth-on one is very good, so I might pick up some of that as well.

In regard to pressure chamber, I was planning to do around 60psi (until the air leak, haha). And I want to get a vacuum chamber eventually but I wanted to see how the pressure setup works first. How would the vacuum chamber make the mold-making process more efficient? Just curious. I thought that that would involve throwing the mold in BOTH the vacuum chamber AND the pressure pot. Wouldn't that take longer? Maybe I have the wrong idea.

But thanks! Good luck to you in your cap-making :)

Thanks you first :)
I think with 50-60 psi, it is perfect, but you can still get with 40 psi.
And with vacuum chamber, it doesn't work like pressure pot. It kills all the bubble in silicone mold. Actually, you don't need to put silicone mold in pressure pot, it just makes bubble as small as possible (it's good for resin but with doesn't work well with silicone)
Vacuum chamber can also work with resin - but you need long time pot life for resin to do with that. For now, I just use vacuum chamber for silicone
You can take a look on youtube for how to using vacuum chamber, very easy to use
P/S: Sorry for my "bad" English  :D - it's not my native language.
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Wed, 06 March 2019, 20:45:26
Thanks you first :)
I think with 50-60 psi, it is perfect, but you can still get with 40 psi.
And with vacuum chamber, it doesn't work like pressure pot. It kills all the bubble in silicone mold. Actually, you don't need to put silicone mold in pressure pot, it just makes bubble as small as possible (it's good for resin but with doesn't work well with silicone)
Vacuum chamber can also work with resin - but you need long time pot life for resin to do with that. For now, I just use vacuum chamber for silicone
You can take a look on youtube for how to using vacuum chamber, very easy to use
P/S: Sorry for my "bad" English  :D - it's not my native language.

Got it. And I had read somewhere that if you're going to use a pressure pot for the resin casting part, it's good to use it during the silicone mold-making process too so that it won't unexpectedly warp when you're pressurizing the resin. Not sure though, I guess I'll try it out and see how it goes!

And your English is fine, I understood you perfectly. Thanks again for the advice!  ;D
Title: Re: zZzCaps : My first foray into capmaking
Post by: gr4v3m4n on Wed, 06 March 2019, 21:22:09
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

Title: Re: zZzCaps : My first foray into capmaking
Post by: fufu279 on Wed, 06 March 2019, 22:33:57
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

For making around 100~200 caps, I think using only vacuum chamber will save a lot of time, silicon molds always take about 6-12 hours to be cured. Although using pressure pot, vacuum chamber not only takes 15-20 minutes to complete but also you can put it outside. And in that time, you can make things with pressure pot.
Title: Re: zZzCaps : My first foray into capmaking
Post by: gr4v3m4n on Wed, 06 March 2019, 22:45:38
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

For making around 100~200 caps, I think using only vacuum chamber will save a lot of time, silicon molds always take about 6-12 hours to be cured. Although using pressure pot, vacuum chamber not only takes 15-20 minutes to complete but also you can put it outside. And in that time, you can make thing with pressure pot.
Haha 200 caps is out of my league my max is 20-30 caps. Most guys here use smooth on's which cures pretty fast thats why it make sense to use vacuum for silicone molds and pressure for resin casting...

Sent from my SM-G935F using Tapatalk

Title: Re: zZzCaps : My first foray into capmaking
Post by: AuthenticDanger on Wed, 06 March 2019, 22:45:54
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

For making around 100~200 caps, I think using only vacuum chamber will save a lot of time, silicon molds always take about 6-12 hours to be cured. Although using pressure pot, vacuum chamber not only takes 15-20 minutes to complete but also you can put it outside. And in that time, you can make thing with pressure pot.

You absolutely want to cure molds under pressure. If they don't cure under pressure they might have small bubbles in the walls that will deform when you cast resin.

Vacuum is certainly useful with extremely thick materials, but is not a replacement for pressure. With materials that are "easy" to pour (up to 15k cps) vacuum is just an extra step that doesn't grant much benefit.
Title: Re: zZzCaps : My first foray into capmaking
Post by: fufu279 on Wed, 06 March 2019, 23:57:04
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

For making around 100~200 caps, I think using only vacuum chamber will save a lot of time, silicon molds always take about 6-12 hours to be cured. Although using pressure pot, vacuum chamber not only takes 15-20 minutes to complete but also you can put it outside. And in that time, you can make thing with pressure pot.
Haha 200 caps is out of my league my max is 20-30 caps. Most guys here use smooth on's which cures pretty fast thats why it make sense to use vacuum for silicone molds and pressure for resin casting...

Sent from my SM-G935F using Tapatalk

 ;D ;D
I worked with about 100 ~ 150 caps every 2 months before making my own cap. After all, that's jst my opinion for the whole process and look forward to seeing your new caps soon  :thumb:
Title: Re: zZzCaps : My first foray into capmaking
Post by: fufu279 on Thu, 07 March 2019, 08:24:12
For silicone its good to have both vacuum and pressure pot just to be safe, but you still get away with only either one. I dont use vacuum just pressure and its fine.
But for resin casting pressure pot is definite the only way. U can use vacuum but as the guy said needs a long pot life resin and really unnecessary.

Sent from my SM-G935F using Tapatalk

For making around 100~200 caps, I think using only vacuum chamber will save a lot of time, silicon molds always take about 6-12 hours to be cured. Although using pressure pot, vacuum chamber not only takes 15-20 minutes to complete but also you can put it outside. And in that time, you can make thing with pressure pot.

You absolutely want to cure molds under pressure. If they don't cure under pressure they might have small bubbles in the walls that will deform when you cast resin.

Vacuum is certainly useful with extremely thick materials, but is not a replacement for pressure. With materials that are "easy" to pour (up to 15k cps) vacuum is just an extra step that doesn't grant much benefit.

These are things I worked with:
There's one left - I didn't use any device, just let it be cured naturally and it has lots of bubbles,
On the right - I just did it with the vacuum chamber (around 15mins) - I'm really sure there's no bubbles left
Maybe I will try Mold Star 30 pressure cooker (I have never used it before)

[attach=1]
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Fri, 15 March 2019, 01:14:34
HUGE Update



Okay, so a lot has happened since last week's update. I probably should have made 2 or 3 posts since then but I was too busy/lazy so I'm just going to throw all of it into this post. I'll try to split them up into logical sections so it's easily digestible.

Let's get started.



I. First Mold



Since last week, I applied the Loctite 545 thread sealant to my pressure pot's air inlet, and is has worked! No more air leakage from there (although there is still some leakage where the hose is connected to the coupler, but I'll have to take care of that some other time.

Without major air leaks, I can finally get pressurizing! I mixed up some Mold Star 30, poured it into the mold box and threw it into the pot. Pressurized to 60 psi and left it alone for around 6 hours.

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As you can see, the sculpt came clean off the mold base! I was surprised and happy about this, since previously I was worried that it would be hard to take off and might get damaged in the process. I had baked the sculpt onto the base, so it was lodged on there preeetty tightly. The sculpt also looks to be pretty fine after the process, no damage or anything. Pretty good results for a first attempt!

Now's time to cast the master, then!




II. First Master Casting Attempt



For all my casts so far, I used Smoothcast 320 as my resin. I had read good things about this, so why not? I mixed it up, added some white and black dye to try to get a nice gray color for fun, and poured it into the mold.

I made a lot of mistakes during this first cast, as I was anxious and excited.


I didn't take any pictures during this, due to shame and my being upset :D Well, except for one.

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III. Second Third Master Casting Attempt (Now with release agent!)



Since the first casting attempt, I made a second attempt but used some Mann 200 releasing agent and sprayed it basically on everything: the mold box, the mold cavity, the metal base and stem. That did not work well either, and the cap came out pretty horrendous (again, didn't take pics :D ). Afterwards, I did a ton more research on the array of release agent products that Smooth-On offers and decided to make a trip to my local Reynolds Advanced Materials, who just so happens to be one of their U.S. distributors. I picked up the following:


The gloss stuff is not the focus, but the other stuff is. With these new products in hand, I proceeded to brush on some Ease Release 205 onto the mold base, stem, and mold box. I then sprayed on some Universal Mold Release, as I believe this spray is specifically for releasing silicone/resin from metal. I had the Wax and 2831 just in case this solution didn't work out, but it looks like it did just fine, luckily. I also sprayed some Mann 200 release agent, which is better suited for silicone-to-resin, into the actual cavity of the mold where I would be pouring resin.

All in all, the third attempt went much better than the first and the second. I was actually able to easily remove the cap from the base, and the stem from the stem insert. Results were still not great, I think I took the cast out of the pressure pot way too quickly (even though I waited for around 30 minutes, and this resin is advertised with a 10 minute cure time) and so the base warped when I was holding it (see pics).

Another thing I was dissatisfied with was I guess just the overall feel of the cap. It felt too light. That, and I just didn't like the feel around the edges. In a word, the cap felt cheap. Cheap is definitely not something I would allow, so back to work, I guess.

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IV. Revised Sculpt + Attempts 4 - 6



I completely removed the front of the sculpt with the small tentacles and stuff and reapplied clay to the front to make it sturdier and more full. (Sorry if you liked the previous design of the front!) I noticed in one of my previous attempts that there were tiny holes along the sides -- looks like there wasn't enough clay in those spots. I also added another layer of clay under the entire sculpt, so that the underside edges didn't look so ****ty/nonexistent. And lastly, I added more clay at the head of the sculpt, to make it look more full and make our friend The Shambler a little chubbier.

I redid the texturing on the revised head and banged my head against the wall for 2 days trying to get a new front + tentacles that I was satisfied with. I'm pretty happy with how it came out.

After all the baking and sanding, it was time for our third mold (I made a second one during the previous ****ty attempts). I did all the same stuff, and the mold came out pretty good again. Time for some casts!

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I was much happier with these results! Might I also add, the feeling of gratification you get from seeing your own cap on your board is amazing. I would imagine seeing my caps on other peoples' boards would be even better :).

Anyways, much better results: the cap feels way heftier with the added mass, there's no holes in the sides, and the butt of the cap looked much, much better.

However, there are still a couple of problems I would like to fix before starting production runs:


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All in all, again, better results than previously. But still not up to my standards. Hopefully I can fix 1 and 2 with my next mold, which hopefully should be done by tomorrow after I come back from work. With any luck, I'll post an update tomorrow evening with the final master! :)





Conclusion



That's about it for this big update. Thanks to anyone that read even just part of this. Hope that it's interesting or that it helps anyone that's also new to this process and wants to try their hand at it. It's definitely difficult and a big learning experience, but it's a ton of fun seeing yourself improve every day. It's also exciting to share progress and get closer and closer to doing production runs of the caps that I can then share with you all in the community. Hope you're just as excited as I am.


Til' the next update!

Stay wonderful, everyone.
Title: Re: zZzCaps : My first foray into capmaking
Post by: weaston on Fri, 29 March 2019, 21:42:22
Love that you are getting serious about the casting process and putting in the time and the work.  I think soon enough you'll have the small issues you want to fix all ironed out and make some beautiful caps.  The first casting attempts look awesome and I can't wait till you have some ready that you think are worthy to sell.

Keep up the awesome work.

 :thumb:
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Mon, 01 April 2019, 21:35:38
Love that you are getting serious about the casting process and putting in the time and the work.  I think soon enough you'll have the small issues you want to fix all ironed out and make some beautiful caps.  The first casting attempts look awesome and I can't wait till you have some ready that you think are worthy to sell.

Keep up the awesome work.

 :thumb:

 Thanks man. Really encouraging to hear that :)

I'm getting closer and closer to being ready to start attempting production runs. I've actually got the stem situation sorted out now, will try to post an update tonight or maybe tomorrow. Exciting stuff!
Title: Re: zZzCaps : My first foray into capmaking
Post by: wtfridge on Thu, 18 April 2019, 10:46:35
A lot has happened since my last update, but I've also been super, super busy with work and have not had too much time to work on this.

For one, I've moved into my new apartment and gotten a dedicated "crafts" room to work on this stuff so it's not too cluttered.

I've also started attempts into multi-shotting the caps. It's really, really hard, and I'm still in the process of learning the most efficient methods of doing so (the sculpt makes it kind of difficult, since it's so intricate). But the first attempts look pretty good, in my opinion.

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Still working on getting colors right, it's a time consuming and very trial-and-error process. I also thought that I'd be happy with how "rugged" it looks, but I kind of wish I had smoothed everything out. Might try and do that and re-cast the molds. We'll see.

Anyways, short update, but wanted to at least post some pics of progress! Hopefully will figure out an efficient way and figure out the colors soon. :)
Title: Re: zZzCaps : My first foray into capmaking
Post by: weaston on Thu, 18 April 2019, 19:42:44
Yooooo this is super dope.  Glad to see some proper casts and the color separation looks nice.  Great progress.

 :thumb:
Title: Re: zZzCaps : My first foray into capmaking
Post by: mezcaline_ on Fri, 14 June 2019, 20:50:33
this is so great, keep at it man. that sculpt is amazing