Molding and Casting

This is the finished crystal in the hilt of my protosaber.


I made the crystal model and mold in Solidworks.

The mold was greased with Lithium grease and the RGB LED was laid inside. I filled the mold with Epoxy resin and waited for an hour while it was clamped shut. The mold opened up quite easily because of the grease, and the crystal came out looking very good.


There was only a small amount of flashing, which cleaned up nicely with a knife. The white spots on the crystal are just the leftover grease, which I wiped off afterwards.

The crystal powered up as intended when connected to 5V, and defused the light very well.

Because of the grease, the mold is re-useable, as shown here. This is the mold after making the crystal.
This was one of my favorite projects of the class.