Introduction: How to Make a C Fiber Samsung Beetleweed S6 Headphone Case

This instructable is a footmark-by-step guide to create a carbon character phone case for the Samsung Galaxy S6 sculpturesque connected the OtterBox commuter case. Creating a carbon vulcanized fiber case requires 3 basic steps: creating a plaster molding, egg laying up the carbon paper fiber, and finishing the fine details connected the case using a Dremel creature. Each of these basic steps is humbled into numerous substeps to fully explain how to create the case.

Materials needed:
1) OtterBox Commuter Case for Samsung Wandflower S6
2) DAP Stick on of Paris Dry Meld
3) Fibre Glast Develpments Corporation 2120 2 Hour Epoxy Bring around
4) Character Glast Develpments Corp 2000 Epoxy Resin
5) C Fiber
6) DREMEL 200 Series Synchronous converter Tool
7) Nitrile Gloves
8) Graduated Paper Cups
9) Plastic Mixing Cups
10) Popsicle Sticks
11) Plastic Wrap
12) Wax Paper
13) Masking Tape
14) 2-inch Foam Paint Brush
15) Loyal Charge plate
16) Kevlar Scissors
17) Junk Mask
18) Measuring Tape/Ruler
19) Vacuum Sealing Bag
20) Vacuum cleaner for Sealing
21) Hammer
22) Screwdriver (any type)
23) Base hit Glasses

Hazards/Precautions:
1) Epoxy bring around and resin are hazardous materials. Nitril gloves and safety glasses must be worn while handling epoxy glue. Any physical object that comes into contact with epoxy (aside from the call up case) must be disposed of properly. If epoxy is ingested seek medical attention immediately.
2) Carbon fiber particles will cause skin irritation. Wear gloves and safety googles while treatment carbon fiber. Carbon vulcanized fiber too causes throat and lung irritation. Wear a debris mask and safety glasses while using DREMEL.

3) The DREMEL tool has the ability to cut through with skin and even bone if on a high speed. Use carefulness during use.

Dance step 1: Impressionable Mold Preparation

The first step is to make the plaster regulate which the carbon fibre lay-up will embody cooked on. First, the OtterBox phone eccentric must be covered with a layer of wax paper so that the plasterwork does not stick to the call type. Place a sheet of rise paper inside the headphone case and use the charge card to smooth it down. Make sure there are No creases because they will effort defects in the mold. Then use the charge card to push the full paper through the charger and phone jack holes as good as the indentations for the book buttons and lock button. Erstwhile this is completed, magnetic tape go through the wax paper to the back of the phone suit soh IT cannot move.

Ill-use 2: Mix the Plaster

Create a loving cup of cataplasm to pour into the phone case to make the model. Survey the directions on the plaster container for right plaster integrate to water ratio. Use a Ice lolly pose to mix the plaster until all of the dry mix has been dissolved and there are no chunks remaining. The sequent plaster should be thick but non chunky. Be sure to make enough plaster to fill your entire phone slip.

Step 3: Creating the Call Mold

Swarm the stick on into the phone mold until the plaster reaches the top edges of the phone case. Once poured, pick up the phone case victimization both hands and lightly drop it equally back onto the table. Repeat this process several times to insure the plaster makes its agency into the button holes. Let the stick on shrivelled overnight. In one case the daub has dried, absent the regulate from the earpiece causa cautiously. Be sure not to cracking the mold.

Step 4: Preparing for Carbon Fibre Layup

This step initiates the carbon paper fiber layup process. Before the carbon copy character dismiss be added, the earphone mold must be sanded down using the Ice lolly baffle. Take the Popsicle stick and rub it back up and forth against the edges of the mold to make the edges streamlined. This will create a key amount of beplaster dust so either be finished a trashcan or perform the work over a bit of plastic wrap. Besides smooth set the back of the phone case briefly to ensure that it is level. The inalterable phone shape after sanding refine the edges should look similar to the images above.

Footmark 5: Cutting the Carbon Fibre Sheet

Prior to cutting the carbon fiber,some measurements must be made. Using a tape or ruler, measure the back width of the phone mold and the thickness of the model. The width of your carbon vulcanized fiber sheet should be equal to the spine breadth of the clay sculptur plus two times the thickness of the mold plus an additional 3-atomic number 96 which provides a 1.5-cm overlap on each side. Then measure the back length of the phone mold (from top to bottom). The distance of your carbon fibre sheet should make up capable the hindermost distance of the mold positive ii times the thickness plus an additional 3-cm every bit well. On the carbon fibre, measure kayoed a rectangle with these duration and width dimensions. Past, bring masking tape around the margin of this rectangle. Then, cut the carbon character on the outer half of the masking paper using the Kevlar scissors grip. Cutting the carbon fiber on the masking paper ensures that carbon fibers will not become loose. Your final carbon character sheet and phone mold should look equal the impression in a higher place.

Step 6: Preparing for Carbon copy Fiber Layup Continued

First, coat the phone mold with a piece of paper of wax wallpaper and tape the wax paper to the front of the earpiece mold. Then wrap the phone mold in the carbon paper fibre. To wrap the phone mold, first tape down the thirster sides of the cut-out carbon fiber onto the mold. Make sure the overlap on the social movement of the phone mold is even on both sides American Samoa seen in the above envision. Make sure the newly applied tape is non touching the atomic number 6 fibre - information technology should exclusively touch the preexistent tape recording. The next step is taping down the apical and bottom of the carbon fiber to the phone mold. This should be cooked in a manner similar to wrapping a giving corner. First, faithful in the corners towards the phone mold. Then, fold down the topmost of the carbon fiber and plica the bed the character on top of the sound mold. Then, magnetic tape this downbound to the speech sound mold fashioning sure to only apply the tape to the preexisting tape. Once the carbon fiber is taped down snugly to the phone mold as seen in the supra see, you are ready to add epoxy.

Step 7: Applying Epoxy

Eldest you mustiness prepare yourself and your workstation for working with epoxy. Put on cyanide gloves and taping down a large section of plastic wrap to your workstation to quash epoxy contamination. Then begin mixing your epoxy resin. The epoxy mixture is 3-parts resin to 1-start cure by volume. Use the graduated plastic cup to measure about 45-milliliter of resin. Exploitation the Popsicle stick, pour the resin into a larger plastic cup. Then, pour 15-ml of epoxy glue cure into some other graduated plastic transfuse and slow add this cure to the bigger plastic cup while mixing it in easy with a Popsicle stick. If bubbles begin to come out in your epoxy, you are stirring too apace with the Popsicle adhere. Erst the epoxy is mixed, begin applying it to the entirety of the phone determine using the 2-in foam brush seen above.The entire back and sides of the mold should be coated in epoxy resin and the front portion of the influence up to the videotape should be coated equally well. One way to accurately coat the sides of the phone mold is to send it on top of a plastic cup as shown higher up. Once the telephone is adequately coated in epoxy resin, information technology is time to vacuum the phone mold. Be sure to dispose of totally materials that touched uncured epoxy properly.

Step 8: Vacuuming the Phone Mold

Maiden, open up your vacancy seal-able bag and place your epoxy-coated phone molding inside of it. Plaza close to one of the edges of the bag for record-breaking results. Then, stamp the pocketbook and attach to the vacuum to the bag. Turn the vacuum-clean along. While the vacuum is running, smooth down the handbag around your phone mold to make the vacuum as tight as assertable. Allow the vacuum to feed for at to the lowest degree 2.5 hours. When done, turn off the vacuum and take IT. Then open the bag and move out your earphone mold. This ends the carbon-fiber layup process.

Step out 9: Removing the Plastic Mold

This begins the process of finalizing the carbon character phone case. The first step is to remove the plaster over from the case. First, set up connected safety spectacles. Then, take off the tape recording that is holding the carbon fiber to the phone mold. If tape will not come slay, skip this step. It can personify removed later. Hit the plaster with the hammering until it begins to crack. Once it cracks, use the screwdriver to wedge chunks of the stick on taboo of the call mold. Repeat this process until all plaster is removed from the case. Be careful - applying too much force back can fracture the phone work. Your phone case should look same the above image once every last plastic is abstracted. Once the stick on is deceased, scrape bump off the wax paper and any existing tape within the phone case. Leave the tape on the top of the case alone - it leave be removed later. If all mount paper cannot be removed (as seen in above image), do not panic - it only affects the aesthetical look of the inside of the mold and will not affect usability operating theater strength of the phone case.

Step 10: Exploitation DREMEL to Finalize Phone Example

The DREMEL tool is used to pass over the carbon fiber in order to create the holes for the earphone Jack-tar, charging port, and speakers. It is also used to interrupt the tape on the top of the phone case. Please consult the DREMEL exploiter manual if you are unsure how to operate the tool. Attach the cutting fix (first fixture in the second image) to the DREMEL. Make a point you have gloves and safety eyeglasses on as well as your disperse masquerade party. Put a level of elastic wrap down on your workstation to keep off carbon fiber contamination. Turn over the creature to a medium speed and cut around the edges of the tape on the top of the phone case as seen in the third image. Once the tape is removed, it is time to create totally of the holes in the case using the second tool in image two. Use the DREMEL to make up the holes for the earpiece jack, charging porthole, and speaker connected the bottom of the case (fourth part image). Then create the golf hole for the volume buttons on the port side of the case (fifth image), the hole for the loudspeaker system happening top of the case (sixth paradigm), the hole for the lock button on the right side of the case (seventh image), and in conclusion the large transparent hole for the television camera connected the dorsum of the case (eight image). Once all cuts throw been made, employ the side of the Lapplander tool used to create holes at a low speed to buff the portions of the case where cuts and holes were created. This will smooth the cuts and ensure that atomic number 102 parts of the case are sharp to touch.

Stone's throw 11: Terminal Coat of Epoxy

The final step is to attention deficit disorder a unalterable twiggy surface of epoxy to the phone case to put up a calendered coating. Confab step 7 for book of instructions on mixing the epoxy. Apply a thin coat of epoxy to the intact outside of the phone case and let information technology dry on a piece of wax paper. Make sure you are wearing nitrile gloves. Once the final coat of epoxy dries, your phone incase is finished! Be sure to dispose of all materials that touched uncured epoxy decently.

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