Gel Mold Fabrication

• Load 1/4" clear acrylic onto laser cutter bed
  Note: Leave the paper backing on both sides of the acrylic when you cut it for a cleaner cut.

• Load compatible hex_acrylic_base file into laser cutter software
  Note: In the files provided, cut lines are red (R: 255, G: 0, B: 0) with weight 0.01pt. If your laser cutter software uses a different stroke color/stroke weight for cut lines, there are several ways to change the files provided to fit your setup. For example, you can load hex_acrylic_base.ai into Adobe Illustrator and change the stroke color/stroke weight of the cut lines to match the settings of your setup. 

• In laser cutter software, set material to cast acrylic with 1/4" thickness
  Note: Setting the material and material thickness in most laser cutter software should load the default laser power and speed for this material. It's likely that you will have to change these settings to achieve a clean cut. You can perform several test cuts with smaller parts until you're satisfied with the cut settings.

• In laser cutter software, align cut geometry with available space on the acrylic sheet

• Execute the cut

• Remove paper backing from one side of the acrylic and leave the backing on the other side

• 3D print outer_ring.stl
  Note: Printer default settings should be adequate for this print. This component isn't structural, so you can reduce infill to reduce print time. 

• Press the acrylic into the outer ring with the paper backing side down.

You'll press against the exposed back of the acrylic base to demold the gel, so leaving the paper backing on will protect that surface from scratches. If your casting surface does sustain scratches over time, you can flip the acrylic base, remove the backing, and have a brand new casting surface.

• 3D print gel_pad_template.stl
  Note: Printer default settings should be adequate for this print. This component isn't structural. 

• Use flush cutters to remove any large flyaway material