Here it is, the most exciting reveal since the Hackaday Prize ceremony — [Eric Strebel] uses the pulp mold he designed and built over the three previous videos. In case you missed our coverage so far, [Eric] set out to design an eco-friendly wireless charger that’s meant to be disposable after six months to a year of use, and looks good doing it.
[Eric] started by cutting up a lot of cardboard and pulping it in a brand-new Oster blender that honestly looks to be pretty heavy duty. Pulping consists of blending the cardboard bits with water until a soupy chili-like consistency is reached. That blender lasted all of 20 minutes before breaking, so [Eric] promptly replaced it with a Ninja, which was way more up to the challenge of cardboard.
To do the actual molding, [Eric] mixed his pulpy chili with ~30 L of water in a tub big enough to accommodate the long brass mold. He dipped the mold to gather a layer of pulp and pulled it, and then pressed the wireless charger in place to create a pocket for it in the final, dried piece which he later replaced with an acrylic disk of the same diameter. [Eric] points out that a part like this would probably dry within ten minutes in an industrial setting. Even though he set it on top of a food dehydrator, it still took 4-5 hours to dry. Soup’s on after the break.
This isn’t [Eric]’s first wireless charger. A few years ago, he prototyped a swiveling version in urethane foam that does portrait or landscape.
Continue reading “Charging Phones With The Power Of Paper Pulp” →
When we last checked in with prolific prototypist [Eric Strebel], he was perfecting the design of an eco-friendly wireless charger and turning his initial paper prototype into a chipboard version 2.0 that takes manufacturing concerns into consideration. At the end of this second video in a series, [Eric] was printing out the early versions of the form by which he would eventually make a brass screen mold for working with cardboard pulp. You know, the stuff that some egg cartons are made from.
In the video below, it’s time to build the pulp mold by creating three smaller molds and then joining them into one horizontal mold. The result is a single piece that then gets folded up into a charging stand, much like the egg carton. [Eric] is using brass screen here, but says that copper would be a good choice, too.
After cutting the brass with scissors and pounding them flat, he uses the 3D-printed molds from the previous video to press them into the correct shapes. Each of the three pieces needs a frame, which [Eric] makes from more brass screen, then stitches it to the mold piece with loose screen threads before securing the unions with solder.
Since the weight of all the water would likely bend the brass out of shape, [Eric] finished off the mold by soldering on a frame of flat brass strip. Check out this awesome process below, and stay tuned for the next video when [Eric] pulps some cardboard and pumps out some eco-friendly chargers.
Does this look too complicated? You could always skip the whole mesh mold thing and shape your cardboard confetti directly into 3D printed parts.
Continue reading “How To Make A Classy, Brassy Cardboard Pulp Mold” →