I have a number of…um, fairly ambitious projects I’m working on right now that I’ve hit roadblocks on. Since the Internet is a marvel of modern technological accomplishment that allows instantaneous access to not only the entirety of human knowledge but also domain experts in every conceivable field of human endeavor, I’m throwing out a request for ideas and suggestions here.
Project 1: The Alien Pod
I have, through a strange set of circumstances, come into possession of an old “bod pod,” a medical scanner designed, I’m told, to measure BMI. It doesn’t work—it’s just the pod without the computer software and such to drive it—and my goal is to turn it into a gigantic alien egg, like the kind in the Alien movies, but large enough to hold a person.
So the plan is to cover this thing with silicone, to make it look like one of the eggs from the Alien movie (which were basically garbage bags and chicken wire covered with silicone). The effect I’m looking for is something like this:
My thought is to cover the pod with silicone (probably condensation-cure rather than the medical-grade platinum-cure silicone I ise for sex toys, whcih is more than $200 a gallon).
Why silicone and not paper-mâché? The pod weighs more than 400 pounds, so it’s very difficult to transport, and the egg needs to be strong enough to survive handling and moving in a truck. My goal is to use it for a photo shoot, with a model halfway out of it, being dragged back in by tentacles.
The problem is that silicone won’t stick to the surface, like, at all. Not even a little bit.
The pod is a stainless steel shell overlaid with fiberglass and with some sort of textured polymer layer on top. Up close it looks like this:
My first thought is to epoxy a whole bunch of short pins to the pod, to give the silicone something to grip. Many years ago, I remember seeing a product that would be perfect for this: small steel pins, about a centimeter or less long, with a ball on one end and a flat base on the other, kind of like so:
They’re quite small, and a whole bunch of them sticking out of the pod like spines on a porcupine would give the silicone something to hang on to mechanically. Trouble is, I don’t know what they’re called or what they’re used for (I vaguely recall that they’re used in aviation, maybe?), so I don’t know how to search for them.
Alternately, any small, cheap, epoxy-able pin or whatever I can glue to the pod might work. I’m also open to other suggestions. Keep in mind it has to stand up to rough handling—this bloody thing is almost unimaginably heavy and hard to maneuver!
Project 2: Machining Molds
I’ve started making alien xenomorph hiphugger strapons and alien xenomorph facehugger gags for sale.
Right now, I’m 3D printing the molds, a 6-part mold for the hiphugger and a 7-part (yes, seriously) mold for the facehugger.
I’d hoped to get maybe ten castings from each mold. In fact, I’m getting 2-3 before the mold is ruined and I have to print a new one. The facehugger mold takes two weeks(!) to print on my 3D printer. Obviously this isn’t sustainable.
I’ve been planning for a while to move to machined wood or aluminum molds, and I have a 4-axis desktop CNC machine:
I’ve been teaching myself CNC milling, but the learning curve is a cliff; I’m getting reasonably good at 2D and 2.5D machining, but man, the molds are complex.
Here’s a 3D model of one part of the hiphugger mold. This is what I’m looking to machine, either in aluminum or even in wood:
As you can see, it’s a complex shape with aggressive undercuts.
I have not been able to make a CNC program to carve this. (One person online looked at this mold and was like “um, yeah, you’ll need four years of trade school plus at least four years of apprenticeship to even think about machining something like that.”)
So, hey, I have the machine but not the skill, why not hire someone to design the CNC program, right? I’ve talked to a few folks online who are like “yeah, pay me and I’ll do the program for you,” then when they see that part they’re like “oh hell no. Hell. No.”
If anyone reading this knows a skilled CNC machinist who can create a program to mill this part, and parts like it, on my machine (a Makera Carvera with a 4th-axis module), send them my way! This is a paying gig.
In the meantime, I’m also exploring ways to treat the 3D printed molds with resin or epoxy or something to make them more durable. Right now I’m only making one facehugger and one hiphugger per month, and even at that slow rate of production, the process I’m using is unsustainable.
So yeah. I have an eclectic set of friends out there with some highly unusual skills, so I’m hoping that some of you might have insights or ideas to offer.