Flip-flops 09.27

Simple flip-flops that beam light from underneath the sole. Nothing more...not even glue...all press-fit.

The main substrate is urethane foam. It was fabricated using the laser cutter. The resolution of the laser cutter is very coarse when cutting urethane because it melts the foam as it cuts it. I roughly approximated the thickness of the cut to 1.5mm. After many many experiments, I decided to go with 100% power at 50% speed.

The circuit is made of flexible copper and smt components. My hope was to cut the circuit board with the vinyl cutter but I gave up after fighting with cam.py for 3 hours. Basically my conclusion is that cam.py can't parse svg files with complex curves.

Some photos of the assembling process:





All the layers are press-fit together using 3mm X 3mm urethane sticks. The sticks go through 1.5mm X 1.5mm holes laser-cut arount the edge of the flip-flops.

The final object is quite dissapointing both visually and functionally. The jaggy edges that were so slick on the screen are coarse on the foam and the resistor-less circuit drains the cr2032 batteries in less than 2 minutes.

Potential improvements for the next prototype: smooth edges, glued instead of press-fit, waterproof, stronger beam effect and a more interesting interaction with the electronics.