How To Make Your Own Sugru Substitute

 by mikey77
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intro2.jpg
I call it Oogoo, an inexpensive silicone clay that is easily made. It can be used as an excellent substitute for Sugru. It can be hand molded or cast in forms. Or, it can be used as a casting silicone. It can be colored any color from white to black. It can also be made translucent to allow diffused light to shine through. It can even be painted on in thin layers. It has very good adhesive qualities and will stick to itself, glass, fabric, paper, wood, and some plastics and metals.

This instructable will show :

1- How to mix and color Oogoo

2- How to cast it or hand form it into different shapes.

3- How to make silicone paint

4- Several interesting uses for Gorilla tape and Gorilla Glue, see steps 3, 7, 12 and 15.

5- How to make a few projects using Sugru and a comparison of Oogoo and Sugru


Since I am mainly interested in using Oogoo to embed electronic circuits in flexible forms, this instructable will also show you how to:

1- Make a soft circuit LED pumpkin head robot display that can be embedded on to clothing.

2- Make cleanly etched conductive fabric circuits

3- Make conductive glue using Gorilla glue.

4- Embed circuits in Oogoo or Sugru


The intro pic shows a few of the silicone shapes that I made using Oogoo and a funky, smirky, flexible pumpkin head robot LED display.


 
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Step 1: How It Works

bluecube.jpg
pic2 shows a 2"x2"x2" solid silicone cube that cured enough in two hours to be removed from its plastic box form.

For years I have been looking for an inexpensive way to create a flexible skin covering for robots and electronic circuits. I have tried several kinds of casting urethane rubber and silicone rubber. They all have their difficulties and either set up to fast or too slow. They are too thin or they are too thick. They are also very expensive in small quantities. Added to that is the problem that they have a very limited shelf life and usually must be used within six months. Sugru is great, but it is not affordable for making larger structures.

I and many others have tried using the inexpensive silicone caulk that is readily available from hardware stores. It is used to seal roofing and glass windows. It works fine but has the problem that it can only be used by putting it on thinly and waiting a long time for it to cure. It is also hard to work. It must be smoothed immediately while it is very sticky. Otherwise, the surface cures quickly and then forms a gummy film while the inside remains soft and wet. It has a smoothing time of seconds rather than minutes. If you put it on too thick the inside will remain soft and can take several days to finally cure. People have tried all kinds of additives in an attempt to make it cure in a more useful manner. I have found those additives to be unusable for my purposes.

So I wanted to add a catalyst that would help the silicone to cure from the inside out rather than just from the outside in.

As I understand it, 100% silicone caulk works by the moisture in the air initiating the polymerization of the silicone. So it cures from the outside in and as it does, it allows the water vapor to slowly seep inside and eventually cure the unexposed silicone. While it cures, it gives off Acetic acid (vinegar is diluted acetic acid) which is the strong smell you will notice if you use it.

I experimented with quite a few additives to try and introduce some moisture into the uncured silicone. Several of them worked to some degree, but the hands down favorite was also the least expensive.

It turns out that corn starch is highly absorbent and when sitting around in an open box it will absorb moisture from the air. It is an extremely fine powder that diffuses evenly in mixtures. By adding the right amount of corn starch, the sticky silicone is somewhat stiffened and very quickly starts to set up from the inside out. While it still sets up faster on the surface than in the middle, the whole thing will set up in five minutes to 2 hours no matter what the thickness. The actual curing time depends on the temperature, the humidity, the amount of corn starch added, and the speed at which it was mixed.

So that's it. Oogoo is corn starch and clear silicone caulk mixed together and then molded by hand or by forms to create just about anything you can imagine that needs to be adhesive initially and solid yet flexible when cured.


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nonsequiteur says: Feb 25, 2011. 3:55 PM
I find a wood screw works best for cleaning out the tip of the caulk tube, if you dont use the caulk for a long period of time the caulk will eventually cure around the screw, but then all you have to do is grab it with some pliers and pull it out and it will pull the cured silicon plug out with it.
slysimon in reply to nonsequiteurJun 16, 2013. 8:39 PM
I am currently half way through renovating my house and had a great idea the other day. Quite often I will use a number of caulking type tubes (caulk, grip fix etc.) of the same type in one day. I used to always use the new supplied tip with each new tube. Now though if I am using another tube of the same substance I use the old tip and save the new one. I have quite a small collection now. So if I now leave half a tube unused for a period of time and it's too difficult to clean out I have the option of using one of my spare tips.
bazketmakr says: Apr 8, 2011. 3:01 PM
I tried to make custom orthotics for a pair of sandals today. I just globbed the sticky stuff in where the arch is, dusted my foot with cornstarch, and put the shoe on. I smashed it a little with my hand, to make sure it stayed under the arch, and then just left it there until hardened. I did one foot at a time. It seems to have stuck to the leather just fine, and i am going to try wearing them tomorrow. i am very happy for this alternative, as the expensive orthotic i currently have does not fit every shoe...thanks for a great idea! I had been buying alot of sugru, and am really tickled to find a less expensive alternative!
slysimon in reply to bazketmakrJun 16, 2013. 8:18 PM
What a fantastic use for this great 'ible. I have many shoes that would benefit from a custom orthotic.
I would love to know how they are holding up? Do they last as long as the rather expensive consumer ones?

Thanks
SS
jackowens says: Jun 15, 2013. 8:48 PM
So this is basically like soft rubbery glue?
mikey77 (author) in reply to jackowensJun 16, 2013. 11:52 AM
No, it is more like inner tube rubber except it is stretchier and not as tear resistant.

It can be glued with silicone to PLA and acrylic,
jackowens in reply to mikey77Jun 16, 2013. 12:52 PM
Thanks!
adisharr says: Jun 13, 2013. 11:39 AM
I'm kind of surprised to see this from the author of this instructable. Believe it or not, some people don't have a lot of time to try out ideas.

I might be getting crazy here but is it frowned upon to ask questions here?
pnsgal says: Nov 22, 2012. 9:24 PM
Has anyone tried Durham Rock Hard putty (powder) mixed with the silicone?
mattbeowulf in reply to pnsgalJun 12, 2013. 8:17 AM
I am not familiar with that product, but I have used plaster of paris in place of cornstarch -- almost 50/50 mix, if I recall correctly. Worked well; end result was like plaster, but hard and squishy instead of hard and chalky. Might be similar... I suspect concrete products would also work. Some day I'm going to try casting a silicone/concrete washbasin...
mikey77 (author) in reply to pnsgalFeb 20, 2013. 12:22 PM
(removed by author or community request)
yellow2121 in reply to mikey77Mar 22, 2013. 7:32 PM
Is it really that wrong to ask if anyone has tried an experiment before trying it yourself? Harsh respose to a simple question, not really in the spirit of Instructables.
explosivemaker in reply to yellow2121May 17, 2013. 11:50 PM
I concur.

I don't think it would work well.....but an intriguing idea if someone has an extra can with some left.
TechGnostic in reply to yellow2121May 11, 2013. 4:38 PM
Yes - I'm on side with yellow2121.

Why shouldn't somebody ask if other, similar experiments have been tried?

What is the point of this *community*, if not to share ideas, knowledge and information?

Yellow2121's question is as much a suggested idea as it is a question, and valuable for that reason.

I think your response should be rethought, mikey77. (I am following the 'be nice' policy here....)
dmorell1 says: May 30, 2013. 9:16 AM
Question, can I use epoxy instead of Gorilla Glue?
Where I live they don't sell it and none of the other brands that are similar to Gorilla Glue.
cattibalistic says: Nov 11, 2011. 9:25 AM
Does anybody know if potato starch will work for this?
alsinel in reply to cattibalisticApr 7, 2013. 5:05 AM
Yes, it works. Not having corn starch at hand I used potato starch twice. Got perfect results both times.
explosivemaker in reply to alsinelMay 17, 2013. 11:51 PM
Thanks for noting.
t1d says: Dec 17, 2012. 4:48 PM
I tried Kool-Aid as the colorant... The powder does not dissolve in the silicone. So, it adds a grainy texture to the mix and does not impart the color very well. Further, the color leaches out of the dried oogoo. The ascorbic acid did not seem to effect the final product.
veeguy in reply to t1dApr 7, 2013. 11:22 AM
This might make a great practical joke material! Use a grape Kool-Aid to mold a squeeze type hand exerciser or similar item and hand it to your "chump" to try out. They will exercise their hands by squeezing it, and end up with purple palms! Priceless, and the color will wear off in a few days -or so...
veeguy says: Apr 7, 2013. 10:44 AM
I just want to throw this out there... There is an auto racing supply shop in our city that is housed in a Geodesic dome building. I've been buying stuff from him for years for my race car. One time I was in there, and I noticed he had silicone caulk for sale by the checkout counter. He always had small tubes of automotive silicone gasket sealer, but these were large caulking gun size tubes. As I thought this was a strange item for his store I asked him about it.

He told me that he had actually built the large dome structure his store is in. There are a hundred or more large triangular panels joined to make the structure, each one with 30 or 40 feet of joints. When he had built it, he used a silicone caulk to seal the joints ( the construction method is: panel-silicone rubber gasket-panel with a bead of silicone caulk on the outside, covered by aluminum flashing) the original Home center type silicone started failing after about 2 years, causing leaks. He wrote to some other dome owners he knew and was told to buy either 100% silicone aquarium sealant (expensive!) or "contractors grade" 100% silicone caulk, and to remove the old caulk and reseal with this stuff. He took their advice and it had been over 9 years without a single leak. He was so impressed that he started stocking the "contractor grade" stuff (both to sell and have on hand "just in case") It really didn't cost much more than Home center caulk, so I picked up a tube.

A few weeks later, I ran my aluminum duck skiff on to some rocks and ripped about a 16" gash in the bottom. I took it home, flipped it upside down, hammered the ragged edges flat and used some sheet aluminum to make a patch. I put a bead of silicone around the hole and pushed the patch in place. I opened my toolbox to get a drill and my Pop rivet gun -found the drill and the rivet gun , but no damn rivets! My brother-in-law must think rivets are magically replaced by the Pop rivet fairy, because he was the last one to borrow the rivet gun and had used *every* *single* * rivet*!. (I always suspected him of being feeble minded, as he married my sister but this proves it beyond a doubt.)

I didn't want to run to the hardware store, so I put a sandbag on top of the patch, and went in the house for a cold one or two or.... A few days later, my son needed to work on his car in the garage, so he moved the boat behind the garage. It sat there from October until the opening day of fishing season in May. I was out on the water with my son drowning worms, when I noticed the patch on the bottom of the boat. I also remembered I had never gone back and riveted the patch to the boat. It was simply "glued" by the silicone sealant. That was about 2004..

I now have a new Bass Tracker boat (sweet!) and my son has the old duck skiff, with the original 8 year old glued on patch. No leaks, no runs, no errors!

OK, this has been a long rambling pretense to this point, but there seems to be a lot of variability to "100% silicone sealers." Some seem to have durability measured in months, others in years or even decades. I'm about to pull my Formula Ford out of it's winter storage for the season, so I'll be needing parts. I will buy some of the contractor grade silicone and a tube of the home center stuff. I wonder if anyone has tried certain brands or types and found a clear winner? If not, I'll try your excellent idea with both, and report back ASAP. I can think of about a dozen places where I want to try oogoo, thanks for the idea!
alsinel says: Apr 7, 2013. 4:37 AM
Yes. Not having corn starch at hand I used potato starch twice. Got perfect results both times.
Spaceman Spiff says: Apr 3, 2013. 6:18 PM
Found these at walmart but wasn't sure if they would work. Can anyone confirm if these will work. First is an all-purpose silicone "sealant". It was the only thing I could find that came close to silicone caulk, since it was literally right next to the caulk and the forbidden GE Silicone II caulk. Second is an oil based paint (at least I'm pretty sure it is). I couldn't find if it was linseed oil based (or if that even matters?) so I wasn't sure if I should get it. Any help would be great. BTW awesome write up!
01.jpg02.jpg
mikey77 (author) in reply to Spaceman SpiffApr 5, 2013. 8:51 PM
Yes, that looks like the right silicone. It should say 100% silicone on the side.

The paints should also work to color the Oogoo.
willrandship says: Sep 30, 2012. 1:49 PM
So, does it have to be 100% silicone caulk? Also, does it have to be clear, or is that just your preference so you can dye it?
mikey77 (author) in reply to willrandshipSep 30, 2012. 9:36 PM
100% silicone works the best. Colored silicone can be used but the coloring additives make it less flexible and and less adhesive.
escapefromyonkers in reply to mikey77Mar 20, 2013. 5:33 PM
luckily i found this , without having to read through the 400 plus comments. i thought i bought clear,but bought white, i now have bought clear, however i realize tat the white is at its expiration date. It seems the silicone caulk has about a 1 year expiration date from time bought. Something to keep an eye out for. i bought it the first time about a year ago, but got sidetracked.
I also noticed that the brand of silicone caulk i bought has two types that are clear and give off the vinegar smell, they stick to different surfaces better, one for bathrooms, one for windows household, i will use them all and see what happens. My original question was concerning the colored caulk, and i caught the answer, It should still work for some uses, i noticed the artist paints in tubes are linseed oil based, and i have linseed oil to thin. hopefully we can get a cliff notes of what all the different mixtures , such as talc and chalk and bicarbonate soda have worked for something or not. I know the original baby powder from talc also had additives, when i was a scuba diver, we didn't use the baby powder on our dry-suit seals, only talc from the pharmacy, the perfumes and additives could cause the seals( latex) to breakdown.
Great information and thanks to all for sharing their trials and errors. I agree with the early response od do it and see what happens, as long as it is not a possible dangerous reaction. The added bonus of thinning the silicone for mold making and quick drying, i will also try. Thanks for the info.
Stoffel21 says: Mar 14, 2013. 1:33 PM
I made this yesterday and it came out excellently well…except I *really* need to find a way for there to not be the vinegar/acetic acid smell. I’d like to make products with this, but I can’t have it smelling of vinegar. Has anyone found a way to neutralize the vinegar smell?
benip90 says: Mar 6, 2013. 7:18 AM
Dribbling over the possibilities, so I tried this with some cheap silicon sealant from wilkos (uk), and it took a little while to cure for a 3mm thick item (nearly an hour probably not enough corn starch but made a very flexible part), using an acrylic sheet for backing. Really good smooth results.
Cant wait to make a soft robot you are amazing
dwrocketman says: Feb 25, 2013. 1:28 PM
awesome brother! thank you very VERY much!
mikemorana says: Feb 19, 2013. 4:30 PM
How well does oogoo handle hardware like nails and screws once it has cured? Has anyone tried drilling holes through it?
I've got a project where I need to fit a tube through a stopper (not necessarily air tight). I'm thinking of using Oogoo to make the stopper since the glass is an odd shape and drilling a 3/4" hole through its center.
Feasible?
mikey77 (author) in reply to mikemoranaFeb 20, 2013. 12:26 PM
You can drill holes through it. But they will be smaller and somewhat ragged.

A better way is to cast the hole in the Oogoo as you cast the stopper and use a 3/4 inch metal or plastic tube to create the hole. You can then remove it and replace it with a more permanent tube.
boom man56 says: Feb 11, 2013. 8:51 AM
can you make it with out 100% corn starch?
edo4 says: Feb 1, 2013. 9:25 PM
Has anyone tried using powdered tempera paints for coloring? Curious to know if that works or not.
sshirena says: Jan 31, 2013. 1:17 PM
Oo. Don't have to buy shares. Can just make some myself!
tktaylor says: Feb 7, 2012. 12:31 AM
People have been commenting that it can be irritating to skin, but that is only during the curing process, correct? If I can stand minor potential irritation during the curing process, then it should have no ill effects once it's cured? I'm assuming that's correct since there's plenty of personal use silicone products like wristbands and stuff. Is this a safe assumption?
shannonlove in reply to tktaylorJan 25, 2013. 12:03 PM
Literally anything can provoke an allergic reaction. That is because the problem is not in the substance itself, but in the individual's immune system. Once the system misidentifies a substance as a threat, it attacks it an all the body parts touching the substance.

People prone to allergic reactions just have a "programming error" in their immune systems at a low level. Once that happens, you can get reactions from a wide array of substances that perfectly innocuous.

The major source of chemical irritation in this case is going to be vinegar in the silicone. It is an acid and it is pure i.e. undiluted by water. Back in the day, when vinegar was widely used for many processes, people were killed by breathing vinegar fumes because the acetic acid destroyed their lungs.
nattyclem in reply to tktaylorMar 15, 2012. 9:52 AM
Well, I recently tried making a practicle joke from this. I left it for two whole weeks in the open air and ended getting a relatively large allergic reaction.
I dont have that sensitive skin but this rash like thing is rather bad.
I hope this helps you.
Also if you are making jewelary try testing a small bit of it before doing anyting to adventurous.
pirobot668 says: Oct 27, 2012. 4:01 PM
Has anyone used Cabosil? Ultrafine silica powder, a gallon of the stuff weighs about 2-3 ounces. Enormous surface area/volume ratio, slightly hydroscopic. Should have enough moisture....
Since it is totally inorganic, and based on silicon, should be compatible and not rot.
dbliss3593 in reply to pirobot668Nov 19, 2012. 9:38 AM
Isn't silica carcinogenic?
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