How to prepare Housing process V4
Design concept:
-fully waterproof
-as small and thin as possible
-adapts to body curvature
-provides sensor identification and placement information
IMG_0601.JPG
Material and Resources you will need:
Teflon : TEFLON 8545K28 R PTFE Sheet, 1/2" Thick, 12" X 12".
Hot Glue : Dual Temp glue sticks 10" length
Hot glue gun
X-acto knife
Mold release spray
Metal clips
Access to CNC router. Ball end mill 0.125.

Providers, resources and consultants used for the SWAP project
Teflon: http://www.mcmaster.com/#bars-(made-with-teflon-ptfe)/=ctyzad
124.54$ each
Hot glue: www.stanleytools.com
4.39$ each
Mold release spray: www.reynoldsam.com

Other useful resources:
For CNC router services: www.**gpimodels**.com

Material usage estimate:
Tefon: Makes 3 sets of molds per 12"x12" sheet
Hot glue: makes 3 sensors per 10" glue stick

Files:
mold set_lower part (7x7x 1.3cm aprox.)



mold set_upper part (7x7x 1.3cm aprox.)





Instructions:
Watch this video on how to encapsulate a Wocket, and follow the steps below.
http://vimeo.com/22750948

Safety considerations:
Wear protective gloves when handling hot glue. Wear protective glasses when close to a functioning milling machine.
Step 1. Prepare Wocket
You should have the battery painted as required for your needs. For our project orange and green sticky labels were printed with an A or W and were adhered to the Wocket.
To prepare the Wocket for housing, just press the connecting wires down as much as you can -as shown in video- to prevent them from sticking out of the housing.
images_video_housing_copy_01.jpg
Step 2. Prepare Mold
Spray the mold release agent on both sides of the mold. One or two times should be enough . Keep spray 6" far from mold. The layer of mold release agent should be thin and have no drops visible. Excess of agent will deteriorate hot glue.
images_video_housing_copy_02.jpg

Step 3. Pour Hot Glue On Lower Mold
The hot glue gun should be hot, so it is best to plug in the hot glue gun 20 minutes before starting the housing process.
Hold the lower mold and poor a gentle layer of hot glue as shown in video. Keep hot glue inside mold shape as much as you can. It should be done continuously and carefully to avoid air bubbles, but has to be done fast so that hot glue will not harden.
images_video_housing_copy_03.jpg
Step 4. Place Wocket
Quickly after you pour the hot glue, grab the sensor with your hands -try to touch only the edges to avoid damaging circuit- and place it as shown in the video, with the metal plates on the connector facing you. Push it down as much as you can -again without touching much of the circuit- and make sure it stays vertical. A significant rotation of the senor towards any sides will cause problems when connecting sensor with charger.
images_video_housing_copy_04.jpg
Step 5. Pour Hot Glue Over Sensor
Quickly after placing the Wocket, start pouring hot glue over the sensor and battery, as shown in the video, continuously and quickly to avoid air bubbles or hardening.
images_video_housing_copy_05.jpg
Step 6. Clip Molds Together
After finishing, place the upper mold on top, press molds together hard, make sure the mold edges are aligned, and then clip.
images_video_housing_copy_06.jpg
Step 7. Harden Hot Glue
Place mold in a freezer for 5 minutes.
images_video_housing_copy_07.jpg
Step 8. Remove The Wocket From Mold
Remove the Wocket carefully as shown in the video, pulling from the flash excess.
images_video_housing_copy_08.jpg

Step 9. Cut Flash Around Housing
Using a sharp X-acto knife cut all the flash excess and clean the connector area avoiding any metal contact with the connector metal plates.
images_video_housing_copy_09.jpg
Done!