My instructable is going to show you how to make a skull ring using only 3d printing and pewter casting. Therefore, you need a 3d printer with plastic charged, a pewter caster with pewter, Dremel, Exacto knife, a wooden stick(min10cm), saw(to cut the wooden stick into size), sandpaper, pencil(to draw where you will put the runner), clamp, paints&fake diamonds(if you want to decorate) and more than two polyurethane foams.
Step 1: Find Your Design and Sketch Your Ideas
If you go to TinkerCad you can look for other people's work. Take the one you like the most or the one you would like to make.
After, you have to sketch and jot ideas that you have in your mind about your project.
Step 2: Make a 3d Model
Now, you will make a 3d design of your ring. While you are doing this, you can use your sketches. After print your design file out using 3d printer to see the size and other details.
If you printed your design, check the size and see if that is good or not. If the size isn't good, do it again until it is satisfying.
Step 3: Make Your Final Design
Finally, you will start to make a final design. I will split the process into three parts because I had to use different materials for all three parts of the ring(head-plastic, jaw-plastic, ring-pewter).
1. I will make a 3d file of head and jaw of the ring. Then I will print it out with the 3d printer. Since you need a lot more support materials, it is better to rotate a bit so you can use the least amount of support materials(it is better to have least support materials as possible). After printing out head and jaw, you will take support materials out and smooth rough parts.
2. If you cleaned and smoothed all the support materials and rough parts, you will color the skull and the jaw. If you don't want to do this, you can skip. If you finished it, you will dry them for few hours.I used Shinhan watercolors black, lemon yellow, red, Prussian blue, Viridian and white. After that, you can also put one(makes antique mood) or two(makes loyal and valuable mood) fake diamonds.
3. Secondly, I will pewter-cast the ring part. To do this part you have to know the size of the polyurethane foam and you have to have two polyurethane foams. If you know these two things, you will put 'hole' ring and the cylinder(this needs to have the same diameter as your wooden stick) to the box which is the size of a polyurethane foam like the picture attached. You shouldn't put them until the end but put it until half of their height. You have to do that process again but your 'hole' cylinders have to be on opposite side. Make sure in the end, you have to put them in the separate files and group them.
4. Now you will mill your two files and put them together. You have to cut the wooden stick to the size of the hole and put it in so you can prevent polyurethane foams from separating apart during pewter casting. You also have to stick them really hard using rubber bands to make sure there is no space between two molds.
5. Now you can start pewter-casting. If you finished it, leave it for 15-20 minutes so it drys. If your ring came out successfully; First, put it in water to cool them down. Second, use Dremel and sandpaper to smooth the ring and to fit the skull nicely with the ring.
If you've finished all the steps above, you are ready to glue them.
Step 4: Gluing and Drying
If you have the skull and the ring which fits skull nicely, it is time to glue.
You will use ___ to glue the ring and the skull
1. In the first part, you will glue the head of the skull and the ring. You will spread the glue between the head part and the ring. If you've done it, pressure a bit, then lean it on the wall(or a vertical thing) for 20-30 minutes.
2. After 30 minutes, you will glue the jaw part. This time, you need something to pressure the jaw and the ring. So you will spread the glue between the jaw and the ring(while you are doing that, make sure your head and your jaw are parallel). Then you will push the head(top)-ring-jaw(bottom) using clamp
But make sure you don't push them too hard because the pewter can bend.
Step 5: Finishing
Now your ring is almost finished. If you want to skip this stage, it doesn't matter.
1. If your paints are coming out or stick onto your finger, you can use transparent nail polisher to make the ring shiny and not sticky.
2. Also, I thought it would look better with gold teeth so I colored the teeth in gold. So I colored the teeth in gold paint and drew the outline with black paint.
After that, you can dry your ring for few hours to dry and then you can start wearing it:)