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This [[Training Ventures|TV]] is tailored for the 152 engineering class. This page will describe the steps of designing and fabricating a vacuum formed shell for the 152 robot. This page will also contain links to sign up for the equipment training necessary for completing this training venture and 152 in general.  

This [[Training Ventures|TV]] is tailored for the 152 engineering class. This page will describe the steps of designing and fabricating a vacuum formed body for the 152 robot. This page will also contain links to sign up for the equipment training necessary for completing this training venture and 152 in general.  

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In the example of the orange cat shell at the top of this page, I designed and 3D printed a mold for the shape. After cutting away the excess PETG plastic, I hand-painted the inside of the shell. I used stacked vinyl cutouts for the nose, mouth, and whiskers. I cut white vinyl pieces for the claws. Finally, I added the construction paper ears and googly eyes as the finishing touches. (My orange cat at home--which was the inspiration for this build--has no tail... just in case you were wondering why there's no tail)

In the example of the orange cat shell at the top of this page, I designed and 3D printed a mold for the shape. After cutting away the excess PETG plastic, I hand-painted the inside of the shell. I used stacked vinyl cutouts for the nose, mouth, and whiskers. I cut white vinyl pieces for the claws. Finally, I added the construction paper ears and googly eyes as the finishing touches. (My orange cat at home--which was the inspiration for this build--has no tail... just in case you were wondering why there's no tail)

But now we will [https://www.youtube.com/watch?v=n67RYI_0sc0 pivot], and I will explain a second example robot shell in greater detail with pictures to show you the process.

But now we will [https://www.youtube.com/watch?v=n67RYI_0sc0 pivot], and I will explain a second example robot shell in greater detail with pictures to show you the process. This robot shell was modeled after Darth Vader's tie fighter.

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The following image shows the mold I used to attempt the shape of Darth Vader's tie fighter. I used the dome-shaped 3D print mold in conjunction with a scrap piece of wood that I cut in half and modified in the wood shop. Notice that after vacuum forming, the plastic did not draw down all the way between the dome and the two wood pieces.

The following image shows the mold I used to attempt the shape of Darth Vader's tie fighter. I used the dome-shaped 3D print mold in conjunction with a scrap piece of wood that I cut in half and modified in the wood shop. Notice that after vacuum forming, the plastic did not draw down all the way between the dome and the two wood pieces.

[[File:Robot Mold Example.jpg|500px|none]]

[[File:Robot Mold Example.jpg|1000px|none]]

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I drew several shapes in Inkscape that would compose the features of the tie fighter. These shapes would be cut out of a scrap piece of vinyl on the vinyl cutter and act as a mask while spray painting later in the process.

I drew several shapes in Inkscape that would compose the features of the tie fighter. These shapes would be cut out of a scrap piece of vinyl on the vinyl cutter and act as a mask while spray painting later in the process.

[[File:Spray Paint PPE.jpg|1000px|none]]

[[File:Spray Paint PPE.jpg|1000px|none]]

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My first round of spray painting was a metallic gray. As you can see, I was a little heavy-handed and impatient with the spray paint which resulted in drips and pooling. Best practices with spray paint almost always call for thin, light coats for best results. Some of the internal topography proved quite difficult to reach with the spray paint which contributed to the drips/pooling. Luckily, the drips and pooling aren't really visible from the outside of the shell, so it turned out ok. I ended up applying two coats of the metallic gray. After the paint dried, I removed the vinyl masking and the painter's tape around the cockpit. However, I left the vinyl masking for the windows in place. I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

My first round of spray painting was a metallic gray. As you can see, I was a little heavy-handed and impatient with the spray paint which resulted in drips and pooling. Best practices with spray paint almost always call for thin, light coats for best results. Some of the internal topography of my shell proved quite difficult to reach with the spray paint stream which contributed to the drips/pooling. Luckily, the drips and pooling aren't really visible from the outside of the shell, so it turned out ok. I ended up applying two coats of the metallic gray. After the paint dried, I removed the vinyl masking and the painter's tape around the cockpit. However, I left the vinyl masking for the windows in place. I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

[[File:Grey Spray Paint.jpg|1000px|none]]

[[File:Grey Spray Paint.jpg|1000px|none]]

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My first round of spray painting was a metallic gray. As you can see, I was a little heavy-handed and impatient with the spray paint which resulted in drips and pooling. Best practices with spray paint almost always call for thin, light coats for best results. Some of the internal topography proved quite difficult to reach with the spray paint which contributed to the drips/pooling. Luckily, the drips and pooling aren't really visible from the outside of the shell, so it turned out ok. I ended up applying two coats of the metallic gray. After the paint dried, I removed the vinyl masking and the painter's tape around the cockpit. However, I left the vinyl masking for the windows in place. I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

My second round of spray painting was a matte black. I applied two coats of the matte black on top of the dried metallic gray paint. Because I removed all of the vinyl masking after the round of metallic gray spray paint, all of the places where I originally put the yellow vinyl masking would now end up black to outline the features of the tie fighter.

[[File:Black Spray Paint.jpg|1000px|none]]

[[File:Black Spray Paint.jpg|1000px|none]]

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