Thread: Wolf(something), in gorgeous pressed horn scales.

Originally Posted by Neil Miller

'WOLFERMAN' perhaps? It is a genuine surname, uncommon, but quite a few american instances of it are recorded. Sounds sort of germanic. Can't find any razor makers, though, and only one instance of the name in the UK - so far!

I have reproduced scales like those before - cold two-part silicone cast of the original scales and two-part acrylic. The main problem with such a detailed design is dislodging air bubbles from the details of the mould before the acrylic sets. It helps to 'paint' a layer of epoxy over the mould first, keeping the brushstrokes slow and trying to force the acrylic into every detail, but some small bubbles nearly always escape detection. The best way would be to make the casts inside a vacuum chamber, of course, but it tends to get rather involved and expensive...

Regards,
Neil

Yes! I think WOLFERMAN is it! Doesn't turn up a single hit from the Sheffield Indexers --not baptisms, burials, census or work -- but considering the trademarks used in the time period, that doesn't mean much. I find myself saying this a bunch lately, but maybe a London outfit?

As to the casting, my intent is to create a proper metal mold that I can use to make more pressed horn scales.

I've had a nasty respiratory bug for the last two weeks and it's really slowed me down, but I should be able to start seriously getting stuff done again soon (like magnafluxing the Regent Street razor, but I'm now pretty sure that's going to be Kens Lewis). Living close to the vasty churning machinery of the special effects industry should mean I've got good resources for mold-making close to hand, and I know some folks in the industry.

Originally Posted by Lemur

A true vacuum chamber is king, but any vacuum will make it better, like a vacuum cleaner and a box.
Vibrations is also good!
Have even tried ultra sound with good results.

The more I think about it, there would be some really solid advantages to getting a very high res laser scan done. For one, I could then digitally sculpt back in the one or two small areas where detail has been lost. I might even be able to correct for generation loss that way... Then it'd just be a matter of getting it printed in metal at a sufficiently high spatial resolution. I know that that 0.1mm accuracy is possible from some of the polymer processes, but I'm unclear if the metal casting printers are equally fine. I'd rather scan, sculpt and print a useful mold than scan, sculpt, print, cast, then pour a mold.

I envy you your razor, and I envy your ability to even attempt the making of a mold for reproductin purposes!

Originally Posted by Voidmonster

... Then it'd just be a matter of getting it printed in metal at a sufficiently high spatial resolution.

All of the metal laser sintering processes I've encountered have been pretty inaccurate - they generally end up with an 'orange-peel' texture on them too. Great for structural components or parts that can be sanded smooth and polished, but no so good for super fine details.

Originally Posted by EisenFaust

All of the metal laser sintering processes I've encountered have been pretty inaccurate - they generally end up with an 'orange-peel' texture on them too. Great for structural components or parts that can be sanded smooth and polished, but no so good for super fine details.

I found a place that does super-fancy CNC with an accuracy of 50 microns. I assume the process involves wheelbarrows of cash.

What I'm considering now is just using Shapeways to make a positive duplicate and cast that. There are just too many upsides to working the file digitally. Like the ability to scale the design for larger blades.

Its amazing what kind of stuff you can get Done for free if you ask. You could get others onboard just for the love of the project. You never know till you ask, and you can only get told no. Good luck !