Hello, dear readers and homemade products!
A wide variety of lamps play an important role in interior decoration.
You can make a beautiful, durable, monolithic lamp from a very affordable and malleable material – casting epoxy resin.
In this article the author of the YouTube channel “Damir Z” will tell you how you can make a lamp of a rather complex shape from epoxy resin.
This project is very versatile, and simple enough to repeat in a small home workshop.
Materials Needed for DIY.
– Castable Epoxy
– Pearlescent Pigment (Metallic) for Castable Epoxy
– UV- epoxy adhesive
– LED wire, acrylic sheet
– Aluminum plate
– Set of screws, washers, nuts, screw rivet – Abrasive polishing paste – Sanding belts – Large tool shop , molds, pigments, dyes for working with casting resin.
Tools used by the author.
– Turbocharged gas lighter
– UV LED flashlight
– Hot glue gun
– Grinder + belt sander, orbital sander
– Polishing set sponges for a screwdriver
– Precise electronic scales
– Scissors, marker.
So, the first step is to make a mold for casting.
First, the master chose the shape of the future lamp profile, and cut out paper template.
The outline of the template is transferred to an acrylic sheet, which will serve as a temporary backing, and can be reused.
Wide strips of thin and flexible acrylic will serve as formwork.
The strips are fixed on the base with a hot glue gun at several points.
Having fixed the strips, you need to seal all joints with an even seam of hot melt glue outside.
To fill the first layer, the master mixes the components of casting epoxy , strictly observing the proportions. To do this, you need to use a measuring glass, or an accurate balance.
Then a small amount of pearlescent pigment (metallic) , and the composition is thoroughly mixed again.
The first layer is poured with a small thickness (about ¼ total), it will serve as a kind of substrate for the wire and LEDs were not near the wall, and did not interfere with the grinding and polishing of the surface.
After pouring on small bubbles float to the surface of the composition. They can be easily removed by quickly warming up the surface with a turbocharged gas lighter .
After 10 hours, after polymerization of the composition, the LED wire can be laid out inside the mold. The wire itself is quite rigid and easy to shape.
When laying, you also need to place LEDs and a wire at some distance from the walls.
Additionally, the master fixed a small bar on the walls of the form, to which he glued the power wire lead. This is necessary so that it does not move while pouring.
Before pouring, it is advisable to check the performance of the LEDs by connecting them to a standard power supply.
For fixing the lamp such a screw rivet is required to the base. Under it, the master fuses a hole in the bottom with a heated screwdriver.
The hole at the end of the rivet is sealed with hot glue.
The master will glue the nut in place with UV-epoxy glue.
Having greased the junction of the rivet with the wall with glue, and installing the rivet, you need to irradiate the glue with an ultraviolet LED flashlight for 3-5 minutes.
Now you can cook new filling compound, and fill out the form with it. This time, the author added a little less pearlescent pigment, making the composition more transparent.
This layer is poured to ¾ of the total thickness. It is desirable that the wires protrude only slightly above the surface, or even be recessed in this layer.
After waiting another 10 hours, you can start pouring the finishing layer.
To accelerate the polymerization of the epoxy resin, the temperature of the composition can be maintained at about 55-60 degrees. So the next layer can be poured after 3-4 hours. It should be noted that after pouring all layers (although they will be quite hard), the product must be kept for at least the period (from the beginning of pouring the last layer) specified in the instructions for the casting resin. The ready-made composition should be used immediately.
The last layer, like the first, is filled with a thin stream. This way you can form various pearlescent patterns. The author is trying to get the semblance of a candle flame.
So, the composition froze, and now you can remove the acrylic formwork. If you are worried that the product may come off badly, then it is better to apply silicone aerosol release on the inner surfaces of the mold before pouring.
The sides are removed first, and then the product is separated from the backing.
Now you can start to surface treatment. The author performs this operation on a belt sander . It is important to choose a low belt speed so that the workpiece does not overheat. The same goes for other grinding tools. Otherwise, the polymer structure will be disturbed, and the overheated areas will begin to crumble.
You also need to monitor the location of the wires and LEDs inside the material, and do not accidentally grind them off.
If the casting is done successfully, then very little grinding is required, just to align the geometry and slightly rounding the edges.
Further surface treatment is performed with an orbital sander. The author starts with a grit of 240, and ends with 800.
After each change of sanding paper, carefully remove the formed dust, especially the remnants of abrasive. Otherwise, a scratch may result from one small crumb, and to remove it you will have to repeat the process again.
The next stage of polishing performed manually with the addition of water. The grain of sandpaper also gradually increases from 1200 to 6000 grit.
Finish polishing with a screwdriver and a polishing pad . In this case, a car polish or polishing paste is applied to the surface.
As a result of this treatment, the surfaces become glossy.
The master used a 10 mm aluminum plate with dimensions of 120 × 120 mm as a base for the lamp. He drilled a hole in the center of the plate and screwed a lamp to it. To avoid scratching the table surface, silicone legs are glued to the plate.
The texture of the lamp is almost opaque, and LEDs with wires are hardly visible from the outside.
When the backlight is turned on, it seems that the entire volume of the lamp is filled with fireflies.
Thank the author for a master class on making a figural lamp from casting resin.
Good mood, good health, and interesting ideas to everyone!
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Author's video can be viewed here.
Hello, dear readers and homemade products!