Mostly I've been sticking LED's into resin. The 'ibles for these can be found which can be found here, here and here.
You could virtually stick anything you wanted into the resin; I decided to go with a “junk robot”! In my dancing robot Instructable I also used a couple of junk robots so if you want some more inspiration check out the ‘ible here
Junk robots are really easy and fun to make. All you need is some old electronic hardware and circuit boards, super glue your imagination and you’re away. I find that the older the electronic components the better. My junk robots were made from parts I scavenged from an old video player and tape recorder, but really you could use just about anything to make them. Just type in junk robots into Google and you’ll see what I mean.
The following will take you through how to make a junk bot, stick it in resin and light him up.
Step 1: Parts and Tools
1. Junk! Any old junk really. My favourite things to use are old electronic parts like motors, capacitors and vintage resistors. All these things can be pulled out of vintage electronics.
3. Core flute (to make the mold)
1. Wire snips
2. Soldering iron
3. Measuring cup
5. Hot glue
6. Super glue
Step 2: Making a "Junk Robot"
You can scavenged electronic bits from different places such as 2nd hand shops (thrift shops) hard rubbish, tips, friends and family. Most people have some type of old electrical hardware sitting around, it's just a matter of getting your hands on some and pulling it apart.
There are some really impressive ones on Google - just type in "junk robots'. These might give you some inspiration and guidance on what is possible. Most of the junk robots that I've made to date have only been very small ones so electronic components work a treat.
Below are some of the ones that I have made in the past.
Step 3: Making Your Junkbot - Part 1
I'll take you through how I made my "Lanky" junkbot
1. First find a suitable motor. I believe that this one is from a floppy disk drive. Other good places to find them are; hard drives, walkmans, old tape players, toys.
2. Next make the arms. I used some vintage resistors and bent them as shown below.
3. If your motor has some holes in the top like mine, you can just super glue them into place. If not, you might have to make your own with a drill and small drill bit.
Step 4: Making Your Junkbot - Part 2
1. Find a couple of small capacitors. These will be the bottom of your legs. Take off the plastic coating. It comes off pretty easily if you score down the middle with a Stanley knife.
2. Remove the 2 wires at the end and make sure that they are flush with the top of the capacitor.
3. Make a small hole in the bottom of the capacitor.
4. Prepare a couple of small vintage resistors by straightening the wires on both ends and trimming.
5. Push one end through the capacitor.
6. The other end will need to go onto the bottom of the motor. Your motor should have a couple of tabs where solder gets added. Add some solder to both the resistor and motor tabs and solder together.
7. Now you have some legs!
Step 5: Making Your Junkbot - Part 3
1. For the head I used a trim pot that has a metal shield around it. You will find these on most modern and vintage electronics and they make great housings.
2. Drill out the insides so the metal casing is hollow.
3. Next I added a RED LED which I trimmed around the edges and super glued into place.
4. Drill a small hole in the middle of the metal casing and push on top of the motor shaft. Glue into place.
TIP: give your junkbot some life by slightly tilting his head and bending his legs.
Step 6: Making the Mold
Step 7: Cast Baby
I have written about casting a few times in my Instructables and gave a pretty detailed description on how to do it. You can find that here from Step 5 if you want more detailed instructions. The one tip that I can give is be careful how much catalyst you use. If you use too much the resin will heat up and crack.
1. Glue your robot onto the bottom of the mold. Position it and make sure everything is where you want it before you start to pour the resin.
3. Mix a batch of resin, enough to over the robot totally and pour. Leave to dry for 24 hours.
4. Once the resin is totally dry, remove the mold.
Step 8: Finishing Up the Resin
1. Use some 400 grit wet/dry sandpaper and sand all surfaces until smooth.
2. Next use a 600 grit wet/dry sandpaper and repeat. You will need to use a lot of elbow grease to ensure the resin becomes clear.
3. The last part of sanding use a 1200 grit wet/dry sandpaper and go over all of the resin.
4. To get that glass finish you will need to rub the resin with a car polisher or Brasso.
Step 9: Adding a Light
- you don't add the diffuser to the LED's
- Break the legs off 4 LED's and glue the tops on the LED's to the corners of the heat shield.
The resin acts as a diffuser and scatters the light really well.
Step 10: The Ones That Didn't Work!
I have noticed that the ambient temperature can have an effect on how the resin sets. On the successful one, I used about 2/3's of the suggested catalyst and this seemed to work fine. It takes a little while longer to set but came out without cracking.
In regards to molds - using a soft plastic like an ice-cream container makes the resin come out super smooth. The sanding only needs to be done to the top of the resin. The problem I had with it is most containers made from this material have rounded corners and I wanted square ones.