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1. Overview
Good for simple circuits or secions of circuits that can then reconnect to larger more complext parts. Use any casting material that will not overheat or melt when your electronics are running inside. Not for the impatients, this can give great results but you might havae to try more than once.
2. Materials
3. Skills required
- Basic mold making experience. Use pre-existing container to avoid having to make a mold if you are just learning.
- Basic Ciruitry building (depending on the application you want to create)
- Very very basic soldering
- Beading electronics
4. Instructions
A--Build the circuit to be casted
If needed, design and test your circuit first using breadboards or any other prototyping method you like.
A scketch of the final soft circuit you will be making will be very helpfull.
The basic idea is simple, using conductive thread and making sure all of your components have crimping beads soldered to them, you will build your circuit just like one would make a necklace by attaching each part to each other and noting the thread when needed.
Design and test your circuit frst
A quick skecth will help you follow
Prepare all your components
B--Making the circuit
One compnent at the time, attach and thread each bead and parts following your initial sketch. Make sure to secure every knot properly and to leave enough lenght for power and ground or any other parts that will need to stick out of the cast to reach for external components.
Knot around the beads
Secure with fray check before each cut
Prepare every part individually first
Some components might not need beads
Attatch series of parts together...
Test small sections as you go
C--The objective
The objective is to go from your traditional schematic or drawing to a recreating made entierly out of thread.
The advantage of using thread over regular wire for casting is that the weight of thread is so light it will not sink to the bottom of your mold, you will be able to easily pull it back out and move your components as the rubber cures and it will also look better inside you finished piece.
From this...
...To this
D--Pour the casting material on the circuit
Place your circuit inside the mold
Add ornements if you'd like
Place your circuit at the bottom of your mold. At this stage, you want to test your circuit for no shorts as often as you can. Use aligator clips and a battery to do so.
Very slowly pour on top
Let it sit
Once you finished pouring, test again and adjust the position of the thread where needed. Once everything seems fine, it is very unlikely that your thread will move much again and the viscosity of the casting material will help avoiding any unwanted contacts at this stage.
D--Test the finished piece
Follow your casting material's instructions on how long to cure. Once time's up, you can release your finished piece and enjoy.
Apply current and see the magic. If there's a problem, you can try reaching in with a needle and pull parts of the thread back out or breaking it.
Test often
And adjust
You're done
6. Possible Applications / Projects using this
The Bright Nights lights.
HELP! I Want to use some BIO plastics or resines to make these. Something like what http://www.3-form.com/ does but available for DIY. Let me know if you hear of something or have a good solution.