This is what my final design will look like. It will be a pendant that will be in the original design and colors of the "Maverick" logo, which will be attached to Kong's necklace by a key chain.
Step 1: Finding the Idea
When this project was introduced to me, I had watched a video by Logan Paul where he got a new Maverick necklace. In the video, he starts saying that Kong should also have a "Maverick Necklace". This gave me the marketing opportunity.
Step 2: First Step: Making the Outline
I made the first outline design on 2D Design. I did this by taking the Maverick design and put it in the CAD file. Then I took the line tool, and manually drew lines around the design.
Step 3: Scaling the Design Down
I took the image that I used to outline the design away, and then I scaled down the design, so it would be a suitable size for Kong to wear it.
Step 4: Different Sizes and Laser Cutting
The files above look the same. However they are different because I had made double.lines in the CAD files. Also, what I have done is that I made the design different sizes so I can see which is the most appropriate for Kong. Also, I added color to the lines, so I could laser cut it to see what it would look like.
Step 5: Preparing for Milling
Now that I have finished and prototyped my design on plywood, I can start transforming my CAD design so I can mill my design into a gelatine foam.
In the first image, I had just converted the colors. But I noticed that the lines I made were too thin and that they would not be large enough for pewter to flow, so I made them bigger. Then, I remembered that I somehow have to connect the pendant to the dog collar, so I tried to make a design so I could put a key chain in the design. However, I noticed that it would be much easier if I just drilled a hole after I had finished the design.
Step 6: Mould Design
This is what my mould looked like after it had been milled. The first mould is a design that Mr. Shaw had made as a demonstration for the class, and he thought that is was like that I wanted it, but I wanted it differently so I remade the mould. The second mould is the type that I wanted, but that was still with the thin lines, so I made them bigger to make the design more sturdy and the design look better. And that design is the third one and it is the one I ended up making my final design in.
Step 7: Pewter Casting
Now that I have finished making my mould, I can start pewter casting. Take a smooth backside of another foam and put it together with the mould with rubber bands.
Step 8: Pewter Cast Design
This is what my design looked like after I had pewter casted my design. (Note: I forgot to take pictures of these designs) The first one is the one where the mould was modified by Mr. Shaw. The reason why I did not like that design was because I had plans of adding color to the design by using cold enamel, but for that to be possible, there must be walls surrounding it so it does not run out. The second is an identical to the one in my final design I had made for backup and to try out milling on it.
Step 9: Cold Enamelling
Now that I have a pewter casted design, I can start putting cold enamel on it to give it color. Cold enamelling was much harder and took much longer than I expected. The reason it was hard was because my design is quite small with pointy edges, and therefore is was hard to get cold enamel into the corners.
Step 10: Design With Cold Enamel
This is what my design looked like after I had cold enamel. It turned out very nice in the colors, however I was also hoping for even brighter colors. Also, because cold enamel is a bit sticky, dust gets stuck in it.
Step 11: Drill a Hole
After the design/pendant is finished, I need to drill a hole the design. I will drill the hole where the beak is. I actually tried to drill a hole in an identical design to see how it would be. I think it was a good idea that I did that because I did not expect it to be that hard to hit right in the center. I used the smallest second smallest drill.
Step 12: Design After Having Been Drilled
The hole I had drilled was very neat and clean. It was right where I wanted it to be, in the center of the beak. By doing that, the hole does not look too obvious because it just look like the beak.
Step 13: Sanding
One of my important design specifications is that it has to have a smooth back to not irritate Kong. Even though the back was already smooth because the backing plate I had used when pewter casting was flat and smooth, I used some sand paper to make it even more smooth just incase.
Step 14: Add a Keychain
I will then connect a keychain from the hole I drill in the design. The key chain was quite hard to add, and to begin with I could not get the ring into the hole. The reason for that is because the design was a bit too wide and because the ring is curved but the hole is straight, I could not fit it in. Therefore, I had to make a bit of the ring flat. Also, I switched up the way the main key ring is connected to the rest of it to make it easier to put it on.
Step 15: Aim Vs Final Design
The first image is what I was aiming for my design to look like, and the second image is the final design. As you can see, it ended up being very similar to each other.