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3D printing + sugru = precision rubber parts! (iPhone 4/4S and 5) + video

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Picture of 3D printing + sugru = precision rubber parts! (iPhone 4/4S and 5) + video
Print your own desktop manufacturing kit to produce precision rubber parts directly onto the iPhone 4/4S or iPhone 5 with sugru !

We developed this project so that makers, engineers and designers could test the process and understand how to desktop manufacture precision rubber parts with sugru. 

The mold and process is not perfect but was developed to demonstrate the potential for using sugru in desktop manufacturing and would love to hear your suggestions.

All the files are open source and free to download from Thingiverse

You can also order your mold directly from Shapeways.

Get your maker mits on sugru here :)



Kudos to carsonlau from the sugru community who created this project last year and inspired to make this. 

http://sugru.com/blog/how-to-mold-precise-rubber-parts-with-sugru/

STUFF YOU NEED:

3D printed mold.
sugru (this project uses just one 5g mini pack)
Washing up liquid
Small paint brush
8 x 10/32 x 1" Hex head bolts (m5 x 25mm) + washers and wing nuts
Toothbrush (we trimmed the bristles from an old toothbrush as it worked better to clean the mold)
Toliet paper
Scalpel
Menda plastic spludger tool (our favourite tool for working with sugru) (or piece of plastic)

You might also need:
Sandpaper
Finger files

 
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Step 1: Prepare your mold

Picture of Prepare your mold
In this guide we demonstrate the process with an iPhone 4/4S. (Molds are also available for the iPhone 5)

To get your hands on a mold, you can find it open source and free to download from Thingiverse ready to print on your 3D printer.

You can also order your mold directly from Shapeways.

In this guide, we used an SLS print from Shapeways which has a higher resolution but is more expensive to print.

To begin with, check that the mold fits together perfectly.
Examine the accuracy of the shut lines and sand or file parts if necessary to make sure they meet properly.
Kyleluvspets2 months ago
I think sugru has an awesome possibility involved with water. I wonder if you could make fishing lures out of them, because it could be formed on to the hook and would fall off. And in sailing, sugru could be used as stoppers on lines and replacements for lost plugs. Or what about sugru fishing bobbers???
clazman1 year ago
1. You used compression molding. Injection molding is what a manufacturer would use.
2. The cure time is outrageous. That would not be a viable manufacturing process.
3. The manufacturer would not, in all likelihood, mold to the product such as to inhibit the opening of the product.
4. The manufacturer would more than likely use a thermoplastic elastomer, such as Santoprene, that could be injection molded and still have elastic properties that would solidify quite rapidly only having to cool down.

5. Sugru has to "cure" thereby making it a suitable product for the hobbyist.
This is an instructable for the hobbyist who wants to use sugru, it's the sugru channel for Pete's sake.
Is there any reason as to why the parts are not available for purchase from Shapeways? Would love to use these but would prefer to order the parts instead of finding a printer.

I guess they just recently put this up, the link is in the first step.

Or, you can just click this link.

projectsugru (author)  TheGreatS8 months ago
the parts are available to download from thingiverse, you could upload them yourself to shapeways We did post them there but it is very expensive to print the parts as they are quite large:(
You could look for a hacker space in your area?
projectsugru (author) 1 year ago
Hi sugru is not yet available in Canada but we do ship to Canada from Michigin, if you order from sugru.com you should have it in a few days...
cgreer61 year ago
Can I get sugru here in Canada? Like is it in michaels? Because sugru looks cool and I want to try it! :D
Edgar1 year ago
You're making Fabricator's History, here...
3D Prints for Molds, not finished objects.
The possibilities are endless, not only for Sugru, but for a lot of stuff...
I always thought 3D printing is perfect for Mold-making, then, it's for anyone's fancy to use any Molding method to produce N objects, in a fraction of the 3D printing time.
Went to my Blog:
http://www.instructables.com/id/3D-printing-sugru-precision-rubber-partsiPho/
Mic1001 year ago
very good idees for me thank's
clazman1 year ago
Nice project but you used compression molding. Injection molding is what a manufacturer would use. Nice job though, but you are simply reinventing the wheel.

2. The cure time is outrageous. That would not be a viable manufacturing process.

3. The manufacturer would not, in all likelihood, mold to the product such as to inhibit the opening of the product.

4. The manufacturer would more than likely use a thermoplastic elastomer, such as Santoprene, that could be injection molded and still have elastic properties that would solidify quite rapidly only having to cool down.

5. Sugru has to "cure" (no heat) thereby making it a suitable product for the hobbyist.
Spokehedz1 year ago
I think I actually prefer the Makerbot version as it looks as if you PRINTED SUGRU which would just be the most amazing thing I could ever think of.
projectsugru (author)  Spokehedz1 year ago
Me too, I love the print lines that sugru picks up. Printed sugru, wowsers, that would be amazing. Now that's an idea we would give someone free sugru to explore !!!!
I agree on the printed sugru idea. That one hit me a few months ago but alas I do not own a 3d printer yet. I want to try and print with sugru though when i do and have some ideas for pushing it through a nozzle. I have also played around with oogoo which I learned instructables. That can thinned out and pumped much easier. Hopefully I can someday show something.
I have the desire, but I lack all other equipment required for such experiments. HA!

Off the top of my head, you would need to have super-high pressure lines run to the nozzle that was lined with something that sugru wouldn't stick to--which is darn near everything! It would be tricky to say the least.
projectsugru (author)  Spokehedz1 year ago
yup, it sure would. sugru can be peeled off Teflon once cured !!!
I completely love this but I don't have an iPhone I have a Samsung galaxy s3.
projectsugru (author)  evilmonkey1261 year ago
darn, maybe someone will develop a mold for the S3 ?!!!! ??

We would supply free sugru to someone that did this...
rgrifford1 year ago
Would this application work for laptops and DSLR cameras? Where can I get the actual rubberized product?
Just click on the link "Sugru" above; it takes you to: http://sugru.com/us/buy

I got some of their samples once (in their giveaway contest). I didn't come up with anything brilliant in the time allotted, but I did try it in a couple of experiments, and it is a good product, though pricey. It comes in several colors, and because it is a clay consistency when uncured, you can really do a lot of things without a mold. If you're not familiar with the product, search "Sugru" in the Instructables search and you will find a load of projects people have done with it.
noremac111 year ago
This is brilliant!
projectsugru (author)  noremac111 year ago
thank you :)
rgrifford1 year ago
I agree "brilliant" if it is durable and is tested on expensive electronic devices such as camera equipment!! It's worth investing in guys!