Honeycomb Scales Composite Material

Honeycomb Scales Composite Material

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Black Beard Projects
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Published on ● Video Link: https://www.youtube.com/watch?v=3veSJl2PFRk


Duration: 11:32
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12,216

Experiments with aluminum honeycomb mesh and epoxy resin to make original handle scales materials.
All materials for this project kindly provided by RESIN PRO find everything here:
www.resinpro.it
www.resinpro.eu
www.resinpro.es
www.resinpro.de
www.art-smola.ru
And use code: "blackbeardprojects" For 10% off your orders (affiliate marketing).

I used two of my previous projects to help with resin cast:
- Vacuum chamber to degass the resin https://youtu.be/BeiW_37rS-U
- Pressure Pot to reduce size of remaining bubbles https://youtu.be/RuQWjLJndro

Index of operation and materials:
0:20 Scrap MDF to make a simple box to cast a silicon mold
1:01 This block on the top will be the shape of silicon mold
1:18 Bondo filler to seal up the box for good
1:47 Specific non-sticking adhesive paper
2:14 Two part silicon for mold making
3:00 Apparently I don't know how to calculate volume of a box, Inserting pieces of MDF to raise the silicon level
3:25 Honeycomb aluminum mesh
3:55 Two part epoxy resin safe to pour up to 5cm thick layers, regular resin is usually rated up to 2.5cm layers, not enough for what I'm doing here. The risk is too much heat and cracks!
4:20 Matt pigments and white mica powder are mixed in
4:45 Resin in degassed to remove most of bubbles that form during mixing
5:21 Resin is let to cure inside pressure chamber set to 1.5-2 bar to shrink remaining bubbles
6:40 Looks like solid pigments are way stronger than mica powders, purple is hard to see in the end
6:50 Spraying the mesh from two opposide sides with contrasting colors
7:24 Mold filled with a thin layer of cork, colored mesh and clear resin
7:40 Filling mesh selectively, a thin layer of resin was poured and let to cure off camera to hold colored resin and prevent leaks
8:10 Cutting the blanks into scales, table saw works decently
8:40 A layer of glossy and clear spray paint was added off camera to simulate high finish without sanding the scales for days.

Thanks a lot for watching, I hope you liked the video!
Suggestions and comments are welcome.
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Tags:
epoxy resin
composite material
resin honeycomb
epoxy scales
resin scales
resin cast
aluminum honeycomb
aluminum honeycomb mesh