top of page
Functional Thor Hammer- April 2019
Exploded View final 3D print design, created with SolidWorks.
Rendered Models of final design.
Kevlar Reinforcement Structure within Hammer
Hammer inside Casting Box
Kevlar Reinforcement Mandrel
being CNC'd for draft.
Kevlar Reinforcement for Pummel (bottom of handle)
cured with Bondo resin in a 3D printed "sandwich" mold.
Pre-preg Kevlar Squares,
cut-outs.
Kevlar Reinforcement Tube and Mandrel, cured pre-preg.
Kevlar Squares, cured pre-preg.
Kevlar Squares, stacked, vacuum bagged, and heated.
Final Kevlar Reinforcement Structure glued together with a two-part epoxy.
3D Printed Hammer, 8 main pieces with small "keys" to align connection point. Glued together with a two-part epoxy, seems were sanded until flush.
Painted 3D Print, to fill-in print lines.
Painted 3D Print and Kevlar Structure,
side by side showing alignment.
Supplies for Casting,
OMOO-25 Silicon Rubber, Smooth-Cast 60D Impact Resistant Urethane Resin, Aluminum Powder, and Cryptolyte (blacklight glow additive).
First Silicone Layer, to support and center 3D printed hammer placement.
Silicone filled to Top, with box sealed shut.
Silicone filled to Halfway Point, to create a two-part mold. 'Keys' added for alignment with second half of mold.
Silicone Mixing Cups used for mold.
Removing the Mold from the box and the 3D printed hammer from the mold.
Final Hammer Mold
Casting Preparation, mold surface dusted with aluminum powder, gel coat added to the mold surface, kevlar structure placed inside, and the mold closed back up into the box.
Casting, the box was tightened with clamps and the mixed urethane plastic was poured through the larger sprue hole at the hammerhead. The smaller sprue hole was observed to make sure the entire hammer was filled.
Removing Cured Hammer from Mold
Final Hammer, after abrading with steel wool for shine, applying shoe polish for weathering, attaching the wrist strap, and gluing leather to the handle.
Final Hammer, glowing blue under a blacklight.
Painted 3D Printed Hammer, used to make the mold; shown for comparison.
Hammer Comparison,
Painted 3D Print (LEFT), Final Hammer (CENTER), Glowing Final Hammer (RIGHT).
Hammer Test,
Smashing tomatoes, grapefruits, and a watermelon.
Click below to see a video compilation showing the build process and hammer test:
(YouTube)
bottom of page