User:Ehaynes7928/ENES-100/Lamination Tutorial

This is a tutorial for lamination. It is built around creating a door handle Sleeve for the Access Project, however; it may be applied to many other designs.

=Preparation=
 * Begin with the general design of the part you wish to create. Ensure you have measured tolerances. Use the dimensions of the design to determine the length and width of the layers you will use. Remember that the finished product may be cut after the lamination process is complete. Not all layers need be identical, that said, it is easier to shape and for the product post lamination.


 * Choose your materials. Your choice for both the layers and bonding agent will affect the properties of the finished product. For the Access Project, I used a can of aluminum. It bonds well with epoxy and is malleable as well as strong. I could have used anything from paper and wood glue to epoxy and plastic wrap to solder and copper wire. Be creative, you can use practically anything.


 * Mark your materials to the proper size, cut them. I used a utility knife and straight edge to mark and score the aluminum can (after it had been cut into a sheet). I did not cut directly through the aluminum, just scratched the surface. Ripping it along the groove I created.


 * The next step is CRUCIAL. If you are using a base structure, ensure you prevent the bonding agent from sticking to this base structure. I used a layer of oil on the door handle to allow me to pry the sleeve off after the epoxy had hardened. Even with the oil, the epoxy does not simply slide off. Unless you are creating a permanent addition, you should ensure your final product will be removable.

=First set of Layers=
 * If your bonding agent requires prep, ensure you have plenty ready for the first set of layers. You may want to apply the agent to the bottom of your layers for better form fitting, or on top to make as little of a mess as possible. Don't worry about getting some on your hands, it will happen, but I recommend using toothpicks and loose leaf paper to minimize cleanup. After the agent has been applied evenly across all layers you're going to add at this time, begin layering them on. Be careful while laying down your sheets, how this is done will determine the strength of the final product. Bubbles, overhangs, lips, and other forms of unevenness can compromise a product completely. Use the correct amount of force while applying layers, more will squeeze out more of the bonding agent, less may not spread the agent properly. Your lamination may not require a clamp, however most will. Lamination without a clamp will leave more bonding agent in between the layers but may not harden correctly. The sleeve I created required a clamp in order to set properly.


 * Once the layers have been laid down, allow the bonding agent it's full set time. More time may be required in humid, or cold environments.

=Layers (Extra)=


 * If your project requires more layers, add them in the same fashion as the first ones. Ensure there is a layer of bonding agent between each layer of structure. Remember, not all layers need to be the same shape, or lay directly on top of one another. However, make sure your layering matches your design's constraints. It is easier to cut and shape the lamination after it is complete than to construct each layer differently. You may not be able to estimate the width of each layer correctly. Not all designs will allow for forming after the lamination process is complete. Some may be cut in between periods of lamination. This is useful when wrapping the design in extra layers in order to keep layers from separating. Try different techniques and designs. Start simple, but once you've made a sample, feel free to explore. Laminations can be very strong creations, or weak depending materials used and how they are created. You can even create a flexible product if you have the correct materials (maybe even mixing your bonding agent with unorthodox substances).

=Finish=


 * Once your lamination is complete, you will need to extricate it from the base structure. Be very careful as you can ruin your product completely if this is done incorrectly. Begin by cutting away excess bonding agent. This will make it easier to pry or snap the product from what was formed on. The more delicate the methods the better. Slipping a razor beneath the bottom layer and gently lifting will likely produce the best results. If your product cracks, don't fret, it may be salvageable. If you think you should start over, don't hesitate, you'll have more practice this time around.


 * When forming your lamination, I recommend using a very sharp implement like a razor or knife. Use slicing strokes and refrain from chopping. This may be a very delicate procedure, as laminations are very susceptible to lateral stress, bending, and torque. However some products may be made to withstand these stresses better than others.