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21 opens
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Alex Berger

Project by

Alex Berger from Inventables
Chicago, USA

General Information

Rep Chi AND stop losing your keys

Like this project Open in Easel®
Material Description Price
Acrylic Adhesive SCIGRIP Weld-On 3

Acrylic Adhesive SCIGRIP Weld-On 3

End Mill Sample Pack, 1/8 in Shank

End Mill Sample Pack, 1/8 in Shank

Needle Tip Applicators

Needle Tip Applicators

Red Acrylic Sheet

Red Acrylic Sheet

Dimensions: 8 in × 12 in, Thickness: 1/8 in, Opacity: Opaque, Color: Red, Surface Finish: Glossy, Cut Tolerance: +/- 1/8 in, Thickness Tolerance: +/- 8%

$6.49

Silver Metallic Acrylic Sheet

Silver Metallic Acrylic Sheet

Color: Silver, Dimensions: 8 in × 12 in, Effect: Metallic, Opacity: Opaque, Thickness: 1/8 in, Thickness Tolerance: ± .05 in, Surface Finish 1: Matte non-glare (1 side), Surface Finish 2: Metallic

$21.49

Two-Color HDPE - White on Blue

Two-Color HDPE - White on Blue

Thickness: 1/4 in, Dimensions: 12 in × 12 in, Surface Finish: Textured, Color 1: Blue, Type: Two-color engravable, Color 2: White, Quantity: 1

$7.49

This project's Bill of Materials is not complete.

$35.47
from Inventables

File Description Unit Price
File-type-blank

Chicago Flag Key Hook.svg

HDPE Milling File

$0

File-type-blank

Key Hook Final 1.svg

Silver Metallic Acrylic Hook File

$0

File-type-blank

Red Acrylic.svg

Red Acrylic Backer File

$0

Download Zip

$0
from Inventables

1

Designing

I designed this project using Easel (www.easel.com).

This HDPE is white on top, but when you engrave it deeper than .05", it reveals a thick layer of blue. Use the following depth settings for each part of the file:

2 Rectangles – .07"
4 Stars – .25" to cut all the way through the HDPE
5 Squares – .25" to cut all the way through the HDPE

2

Milling

Mill the HDPE. I cut this on a Shapeoko 2 with a speed of 15 and a depth per pass of .04". I used a carbide 2 flute straight flute end mill found in the Inventables End Mill Starter Set. The material milled beautifully.

Next mill the silver acrylic hooks and the red acrylic backer. I cut these on a Shapeoko 2 with a speed of 25 and a depth per pass of .02"

3

Assembling

To attach the red acrylic, carefully cover the back of the cut HDPE with Weld-On. Line the red acrylic up and press it against the back of the HDPE. Apply pressure for a few minutes until the pieces are fused together.

After cutting the metallic silver acrylic, you’ll have 10 hook pieces. Each hook is made from 2 of these pieces sandwiched together. For each hook, apply Weld-On to the large flat surface of one piece, then line the 2nd piece up the same way and press them together. Apply pressure for about a minute until the 2 pieces are fused together.

Attach the hooks to the HDPE/acrylic piece one at a time. Put a few drops of Weld-On into one of the 5 square holes, making sure it covers both the inner edges of the HDPE and the red acrylic. Put a few drops on the back of the hook, then insert the hook into the hole. Apply pressure and hold for a few minutes until the hook is secure. Repeat in the other 4 holes. Let the Weld-On dry completely for a couple of hours before using the hooks.

I hung this on the wall using basic mounting/hanging strips meant for photos.

4

Finishing

Lightly sand the milled portions of the HDPE to remove tool marks. This will leave the blue parts a little white/dusty – apply a small amount of mineral oil to restore the color and add a polished finish.

Michael Audette
Very nice. When are they going to let us mere mortals use easel.com? Makercam works (sometimes)...but easel looks to be just what the doctor ordered.
Michael Audette
Alex Berger
Hi Michael, you should have access now! Please feel free to share any projects you've been working on :)
Alex Berger