Maniacal Prozac Bottle Toy

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Back in the shop for the last time for this class, I set up the 4 Axis to make the final pieces only this time I edited the support height and width to be bigger in order to cut down my milling time.

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I got it down to 3 hours of roughing and half an hour of finishing,

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and made sure not to tighten the bolt too much like I did with my previous piece that ended up with lines all over the top of the face.

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While the delrin was being milled I got out the vinyl cutter to make the eyes.

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I sketched out a few eyes with the paintbrush tool and proceeded to watch instructional videos about how to set up the cutter properly.

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Then, after exporting the file in the proper format I opened up Silhouette Studio and imported my file.

Everything looked ok to go…or so I thought.

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But what came out was a mess and I struggled to figure out how to outline the lines I had drawn in Illustrator.

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The paper wasn’t being fed correctly through the cutter but I couldn’t figure out how to move the chassis so that it could feed it straight through. Unfortunately, I just had to give up and rely on printing the eyes at home due to time constraints.

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While the rest of the delrin was milling I played around with how I wanted the sticker to look. Creating slits on the side and cutting different parts out from the original print to place them dilligently on the toy’s face.

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I didn’t want to cover up all the work I had done on the mouth so cutting the sticker in half lengthwise seemed to make sense.

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Once I had the three remaining white pieces I dyed them using the same technique as the first one and for the same amount of time to ensure the color would match.

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They came out nicely.

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I took the Illustrator file I tried cutting with and printed it out on printable vinyl sticker.

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The eyes needed to be a little bigger to hide the puckering underneath from putting a flat sticker on a curved surface.

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And after printing out several labels, I had a lot of cutting to do. But first, I wanted to spray paint the inside of each mouth flat black.

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This was a scary process because there was no room for error and I had spent the last 10 minutes scouring google for tips on how to apply paint to delrin. Not a lot of people had luck with spray paint and this freaked me out.

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It took a long, long time to place tape all around the mouth correctly.

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Getting the angles required putting tiny pieces of the flat edge of the tape along the mouth and pressing hard to ensure no paint would seep through.

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I was very happy to be done with that part, but nervous to begin spray painting!

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At first, I did one at a time — mostly out of fear of something going wrong.

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But after the first round dried I got more comfortable with the process and added two pieces at once.

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And eventually four at a time.

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The result was pretty good but I was cautious about taking the tape off, not to rip some of the paint off with it.

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Despite my careful taping, some of the paint got on the lips of the piece.

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But it was surprisingly easy to take off with my fingernail, which kindof worried me about the paintjob lasting a long time.

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I wanted a crisp, to the point sticker to put on the bottle head, and cutting a circle proved to be very challanging.

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Made a tongue too to try and lighten up the mouth a little, and then I used Gorilla Glue 5 minute epoxy to secure the caps on the body and let it dry for an hour to be safe.

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To my dismay, the epoxy did not hold at all so I had to rush to find whatever I had at home to put the two pieces together securely enough.

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I found some heavy duty 3M double sided thick tape and doubled up on it and stuck ’em on and it kindof gave the effect of having the bottle closed but the child’s lock preventing you from opening it.

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In conclusion, I really solidified my work flow on the 4 axis making these toys and my VectorWorks skills increased as well. While I don’t enjoy cutting or printing stickers at all, creating the Illustrator files was fun and I’m now more comfortable using Photoshop too. I don’t think I’ll ever want to peel another sticker again in my life, and I wish I had tiny scissors at home instead of the kitchen ones I used to cut everything with. If I had more time in this class, I would have loved to make 3D printed pills with faces on them to either put inside the mouth of each toy or find a way of putting them under the cap, sticking out. Clearly, I would have liked to find a different way of incorporating a sticker into my design that didn’t require dealing with puckering but I’m glad I used the stickers in the end because I worked hard on them.

Packaging Design & 2nd Print

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I searched my neighborhood far and wide for the right kind of packaging I wanted. Specifically, I was looking for a slim white bag with minimal logo’s so I could easily cover it up with a vinyl sticker.

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Then, using Illustrator and a free Walgreens font, I created a simple sticker design.

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But realized an oval shape wasn’t going to cover the existing logo completely.

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So I took the oval away and made it very simple and it turned out clean.

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I printed a very small version for the top of the bottle as well and got back into the shop to make the 2nd bottle.

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Unfortunately, I tightened the delrin too hard on the 4 Axis and it resulted in the front of the bottle having ripples.

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Back at home I started playing around with sticker placement after printing out a few more labels.

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I think I definitely need to darken the mouth and I may want to tuck the sticker inside of the mouth first to emphasise the shape.

First Finished Product – Mel N. Colly

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I decided to go with Delrin for the final product because I wanted to revisit the 4-Axis machine and because I wasn’t very happy with the quality a 3D print puts out. So, starting with a 3″ by 6″ piece of white delrin, I took the first VectorWorks CAD model I created because the mouth was bigger and the bend in the bottle shape was more what I was looking for.

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In Roland I added supports and made the size bigger to avoid a long milling time.

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I had to position one of them so that it wouldn’t cut into the bottom angle of the piece, making it hard to sand it down.

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In preview mode it looked good to go so I started the process. 3.1 hrs.

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Made a center hole.

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And loaded the Delrin,

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Set the X axis.

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And the Y at the center of rotation,

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And started milling.

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I forgot how much the 4 axis spits out on the first go.

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Roughing took a majority of the time.

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Finishing only took about 20 minutes.

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Once it was done it took roughly 4 hours and I was happy with the results.

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Even though the mouth couldn’t cut a thin agle at the corners, the gradient it created sort of looked like the inside cheeks of a dogs mouth and I was fine with it.

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I chopped off the supports on the band saw and got out my multiple grades of sandpaper to smooth it down.

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Then it was dye time. Using Jacquard Fabric Dye ( and a cheap pot and strainer, I brought a pot of water to a boiling point.

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Then, added the color intensifier and stirred thoroughly.

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Then the color packet.

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Stirring until thoroughly combined.

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It was the weirdest smelling sauce I ever made.

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Plopped the milled Delrin into the boiling dye keeping it from hitting the bottom of the pot with a strainer.

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Set a timer for 30 minutes and stirred frequently.

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After half an hour I took out the piece and washed it under warm water.

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The result was pretty orange but not as orange as I wanted.

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It wasn’t very sturdy on the table so I sanded it down a little more,

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so that I could get rid of the tiny bulge at the bottom that was preventing it from sitting up straight.

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Back in the pot, to a boiling point for half an hour more.

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Every now and then I needed to add water to the pot to maintain coverage of the Delrin.

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Half an hour more proved to be a great idea.

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I got a nice Nickelodeon orange and the cap from a real pill bottle fit perfectly.

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Then it was time to print out the sticker label I created in Photoshop.

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Borrowing many pieces from a real Walgreen’s label,

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the sticker printed with low ink, unfortunately, and smudged easily the first time around.

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So I printed another one with different printer settings and with the absence of color ink the print out needed to be dried and probably wasn’t going to get much better than this without more ink, different settings or a divergent approach.

I have to wait until the morning for it to dry.

Upon further thought, I want to explore transfer stickers because I’m worried about how I’m going to create an attractive bend in the vinyl sticker over the mouth to create teeth. I also don’t know if it needs teeth. It may be torn strategically at the mouth.



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An hour later I took another look at the printed stickers and tried peeling it off only to realize I had printed on the wrong side!

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So I printed out a sticker and cut out a mouth,

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and even though I had low ink, it printed pretty well and got a good idea of where I want to go from here.

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      • Add pills to the base
      • Sturdy the base with aluminum
      • Add cut stickers as eyes
      • Modify two models to lean back better
      • Buff models to glossy shine
      • Add lips and creases to the VectorWorks model to ennunciate emotion
      • Alter sticker mouth to include happy and side mouth curves
      • Cut cartoonish tongue stickers
      • I’m curious about this process but I feel like I’ll screw it up