This is the procedure I use to make small epoxy resin signs. Most of the process is shown here in chronological order.
-The base is 3/4” MDF.
-The epoxy resin base—any epoxy that rests on the MDF—is 0.200” thick.
-Any of the epoxy resin details—those pocketed into the epoxy resin base—are 0.100” thick.
-The process for machining the pockets on the details was to V carve the perimeter using a 60-degree 2 flute V cutter, then pocket out the area using a 1/8” 2-flute flat end mill.
Designed and manufactured using Fusion 360’s 2D engrave operation for the V groove toolpaths and 2D pocket operation for the clearing.
SPEEDS/FEEDS:
-60 degree V Groove-10000 RPM, 100 IPM, 0.100” DOC.
-1/8” Flat End Mill-18000 RPM, 60 IPM, 0.100” DOC.
Epoxy is Superclear Tabletop Epoxy.
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Colorant is Supercolors Epoxy Resin Color Pigment:
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TIPS:
-First and foremost…Make sure your machine’s table is level in all directions; The epoxy will flow downhill overnight and leave a deficit of epoxy on the uphill side of the pocket.
-Make all facing passes except the very last one .040” above the true top of the sign to leave a protective layer during the 12 day process.
-If the sign has a lot of fine detail, as this one does, do the final facing pass 0.020” above the top of the sign and use an orbital sander to sand off the last bit until the details look right. AVOID OVER-SANDING.
-Cure each pour 24 hours before machining the next feature.
-Once the liquid resin is seated in the pockets, pour extra resin on top for 3 reasons: 1) The resin shrinks during curing. 2) It gives air bubbles a place to rise beyond the top surface of your sign and 3) any dust/debris that settles on the resin before it cures will be machined away.
-Use clear packing tape on the entire bottom surface of the sign so drips won’t stick to bottom when you flood the sign with a layer of clear epoxy.
-Before pouring the final flood layer of clear epoxy over the sign, be sure to wet the entire side surface of the sign with epoxy so the flooding epoxy will flow evenly down the sides and not leave drip marks.
-Before pouring the flood layer of clear epoxy, rub epoxy into the top of the sign to ensure epoxy fills any scratches from the sanding process.
-On all epoxy pours, be sure to LIGHTLY torch the surface of the wet epoxy several times at 3-5 minute intervals until you don’t see any air bubbles popping on the surface. This does 2 things: 1) bursts the bubbles at the surface and 2) makes the resin less viscous (thinner) allowing the air bubbles to rise to the surface more easily.
