Step 2: Wax pattern

To make a ring, first you need to carve a wax pattern. I use a green jeweler's wax to make my patterns.

The wax is carved using a dremel type tool to first rough out the shape and then this is refined using scraping/carving tools and small files. For scraping and smoothing small flat areas (such as the top of the ring) an old small screwdriver works really well. Wax carving is something that requires a fair bit of patience- remember that the better your wax model is the better your finished casting will be.

Here are the basic steps on how to carve a Hal Jordan wax ring (this is the easiest wax of the three to carve.)

1) To carve the wax ring first slice off a section of ring wax that is slightly wider than what the finished ring will be

2) Now open up the hole in the wax until it approximates your finger size- it's better to have it too tight than too loose at this point as you can always remove a little material later on. Then use a Sharpie pen or scribe to draw the profile of the ring on the wax and cut that out of the wax.

3) Now rotate the wax so you're looking at the end of the ring. Now draw the shape of the ring on the wax and remove the excess material. At this point you're only trying to establish the general shape of the ring and thickness of the ring shank.

4) Now switch to the top of the ring. Draw the circular shape on the top of the ring and remove the extra material. Now is when you have to start blending all the contours of the ring using a scraping tool- just work at it slowly until you get the final shape you want.

5) Now cut the symbol into the top of the ring using a Dremel tool and then refine it using a small flat scraping tool.

Once you're happy with the look of the ring you can smooth the finish with some fine sandpaper and steel wool. Wax carving is something that is hard to learn- there have been whole books written about it. You just have to jump in and start carving and go from there.

If you're going to make a glowing ring you have to remember to make the ring tall enough to house the LED and watch battery- this will more than likely require you to carve the wax from a larger block of solid wax (unless you have really small hands.) I've listed a supplier and part numbers for both types of wax below.

The insignia area of the ring should be somewhere around 10mm to 12mm tall, depending on the exact battery and LED you are using and how deep your pattern is cut into the top of the ring. If you need it to be lower you can carefully sand down the top of the LED to reduce the height but unless you find an extremely low profile LED and battery I think it'll be very difficult to get the total height down under 7.5mm to 8mm at the very lowest.

The best way to figure it out is bend the leads on your LED and then hold your battery underneath it. Measure the height of the LED and battery together and then add a little extra for the engraved pattern on the top of the ring. This is of course assuming you're making a Hal Jordan or Kyle Rayner style ring- the Alan Scott ring as I made it would have to be slightly different as I didn't make the band thick enough or wide enough to hold the 3v battery.

I ended up making three wax patterns for the Hal Jordan, Kyle Rayner and Alan Scott rings.

Here's a detailed list of tools/materials:

From- http://www.ottofrei.com

Ferris green ring wax (T200 flat side with hole) part# 121.369
Block of green wax for carving light up ring (this is needed due to the added height for the LED and battery)- part# 121.0706
Saw frame- part# 149.740
Wax sprue wire (6ga.)- part# 121.560
Large carving burr- part# 120.205
Wax file- part# 131.384
Wax saw blades- part# 149.300D
Wax carvers- these are a better combination (one flat and one detail carver) than the blue handled carvers I show in the photos and they're half the cost- part# 121.851 & 121.852

Not all of the tools are absolutely necessary- you can substitute a couple of small flat bladed screwdriver for the wax carvers and you can use regular Dremel burrs for carving as well. Wax files are nice to work with but wood files and coarse metal files will also work.

Otto Frei is a great company to deal with and you don't have to be a professional jeweler to buy from them. I've been dealing with them for nine years and the service is always first rate.

<p>Well, my drawing sucks and anyone I know will outright cast me in an asylum if i told them what I want! The basic idea is to make a frame that would look like the green lantern ring and hide the silver at the same time. For lighting effect i could use tiny LEDs and batteries. This is what I thought initially but could progress the idea further. Meanwhile I'll see what i can do about anything visual. </p>
<p>hi Honus! Is there any way i could make a ring around this ring, like a frame instead? Also can I put tiny leds in the grooves below the ring? </p>
Do you have a sketch or something that sows exactly what you want to do?
The fill/vent sprue, are they sold with the sprue sticks or did you make them yourself
Nevermind figured it, thanks though. On another note, if the whole thing is wax couldnt you heat the unit, let it drain and then cut it? Is this particular silicone &quot; heat resistant&quot;?
<p>Most RTV silicone compounds are somewhat heat resistant, depending on their composition. This particular compound is limited to 395 degrees Fahrenheit so I wouldn't recommend trying to cast metal directly in the mold. Most waxes that are used for pattern making don't melt until around 250 degrees and then you would need to make sure that all of the wax melted out of the mold without leaving any residue. Since you have to cut the silicone mold open to remove a finished cast anyway there isn't really any reason to melt the wax out of the mold.</p>
<p>you should start mass produce it because it looks very unique.</p>
Have you ever thought about using an induction coil inside the ring, coupled with a transmitter hidden inside a power lantern? Would make the ring glow when held near the lantern. I think that would be pretty awesome. Similar to something like this http://www.kokes.net/projectlonghaul/projectlonghaul.htm <br> <br>I think I'm going to have to give it a shot at some point, because how awesome would that be?
I have seen that project before- it's very cool. One thing I thought about was making a ring with a RFID tag in it so when you held it up to the lantern the lantern would turn on.
Metal powder makes the resin look like metal and dye can color the resin.<br/>If I use both together will I end up with a resin that looks like colored metal?
I don't know as I've never tried that. I have seen the powder and the results are pretty nice so maybe it will work. Give it a try!<br>
You should put it on amazon.It would make a great Survival light.
I wanted to mold a clear epoxy sheet to put in front of my kiddos television in the playroom. The tv is 55" x 62" and I have build a wooden casing for the tops and sides. I just want a clear plastic type material in front so they do not damage the tv. I looked into plexi and such but was not impressed. Would this be an option? If so would I build a mold out of wood?
This comes a little late to be of help to you, but anyone interested in attempting to make a plastic sheet or pane should find the the instructions and photos for making a pane of &quot;Break Away&quot; glass (like the props used in movies) of interest. Go to <a href="http://www.smooth-on.com/Special-Effects-an/c1241/index.html" rel="nofollow">this page</a> and scroll down to the &quot;Step By Step Video Sequences&quot; and look for &quot;Making a Breakaway Glass Pane&quot;&nbsp; As a sheet of acrylic is used for the bottom of the form (to ensure a clear surface), you'd likely be better off just using the acrylic. :) The &quot;break away&quot; property comes from the special casting resin sold by Smooth-On.
I think you would have problems getting both sides of home cast resin perfectly flat.<br>You would probably be better buying a sheet of cast acrylic cut to the size you require. This should be a bit bigger than the screen to allow for fixings.<br><br>There are many places where you can buy cast acrylic<br>I have bought materials from http://www.westwardplastics.co.uk/index.php and found them to be reasonable, I was in Bristol and collected in person to avoid delivery charges and they let me take some useful sized bits of plastic from their scrap bin.<br>
The other problem with trying to cast something that large is air bubbles in the casting. You would need to cast the entire thing in a vacuum chamber and it would never be as clear as Acrylic sheet.
Hi there, I was wondering if you think it would be easier to buy a wax ring tube already with the inner diameter of your finger to wear, rather than having to buy and grind out the inside to get it a good fit?
I'm not aware of any company that sells ring wax tubes in specific finger sizes. Removing wax from the inside of the wax tube is no big deal- it carves really easy.
aagh I see, think you for the tip then. I've never done wax carving before so I was just wondering, thank you again. :) You've made me want to carve my own red lantern ring
Cool- I haven't seen a red lantern ring yet. Be sure to post pics when you're done! If you need help or have any other questions just let me know.
Do you know any work around or substitue for having to buy/use the wax sprues. I don't think my michaels store will carry them and that's where I'm going for my supplies. couldn't you just use some left over modling wax to make some up or use some plastic tubing (thinking of my spare air tubes for my fishtank). What I know about silicone is that it's nonstick, it shouldn't stick to the plastic during curing and the model being molded doesn't have to be completely wax, right -other materials can be used: metal, plastic, etc.? thanks. first timer molder-caster.
You can use whatever you want to shape the ring model and sprues- you could even use modeling clay.
hey honus i just follow you said and i modify my green lantern ring and it came out awesome dood im gonna post this in this website check it out
Cool- I keep an eye out for it! I'm working on modding the new movie rings right now. :)
thanks, nice to know modeling clay wil work; I get them free at the school sometimes :D compliments on your craftsmanship! Those wax rings look so smooth!
instead of carving a ring by hand, or sculpting it out of wax, you could take a ring with the basic shape you want, and put it in ballistic gel, remove it, and fill the cavity with wax.
Where can i find a LED light for this?
You can get 10 green LED flashlight keychains that include batteries and free shipping to anywhere at DealExtreme for under $5. They wouldn't fit as they are but the parts might if you carefully extracted them.
radio shack , its where i got mine when i made a iron man arc reactor
Try Radio Shack they have all kinds of them
I bought mine from a local electronics supply but you could try online suppliers like Digikey.
Thannkk Youuu!
and how durable is the glowing one also?
While the resin is somewhat resilient it's definitely not an everyday ring.
How does the glowing ring look with the light off?
It just looks like a plain translucent green,
I have a gas forge that gets to 2500f how hot do you need this to be for silver.... I also have a kiln... which would be better? <br>
That's easily hot enough- the trick is that the burnout oven has a ramp up cycle so it goes from 300 degrees and holds it and then up to 600 and holds it and then goes up to 1300 for burnout and then goes back down to around 900-1000 degrees for casting. All of this happens over several hours- I usually set up the oven so it turns on around midnight and then I'm ready to cast in the morning. Melting of the Sterling Silver is actually done using a gas torch- I've never cast Silver using any other method. Sterling Silver flows around 1650 F depending on the exact alloy.
I plan on making one of your resin rings, and i was curious as to how durable they are. Once it's made how durable are they?
They're pretty durable- it can be worn every day but it obviously won't hold up as well as a metal ring. If you were to step on it you would probably damage it.
if you made one out of gold it would be the coolest thing ever haha.
It would be cool- and expensive!
I love ur rings!!! its so pretty... I want to have them... do u have any other simple ones that I could use for my science project?? &gt;_&lt;
Thanks! I don't currently have any other designs.
Green Lantern is the best.
why dont you sell these
Because DC is extremely protective of their intellectual property.
how do you get that jewelers wax?
It's listed in step 2.
where you buy ring wax?

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Bio: I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop ... More »
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