Lampshade from Recycled Bottle Caps

- Plastic,Craft,Prototyping,Product Design,Opensource

- Plastic,Craft,Prototyping,Product Design,Opensource
HDPE

How to Bend a Plastic Sheet Without Heat or Mold

This guide demonstrates bending a plastic sheet using a method inspired by the woodworking technique known as kerfing, which bends wood without water or steam.

Browse Files

Table of Contents

  1. 1

    Prepare all the materials and tools

    Requirements:

    • HDPE plastic board:
      • 11.8 in x 4.1 in, 0.2 in (thickness)
      • ⌀3.7 in, 0.2 in (thickness)
    • Portable sanding machine
    • Soldering iron
    • Table saw
    • Rope
    1-186ba254193.jpg - Plastic,Craft,Prototyping,Product Design,Opensource

    1-186ba254193.jpg - Plastic,Craft,Prototyping,Product Design,Opensource
  2. 2

    Score the plastic

    First, use the table saw to score the plastic. Cut to a depth of 0.12 inches (3 mm), maintaining a 0.20-inch (5 mm) gap between each cut. Ensure the board is scored perpendicular to the bend direction.

    2-186ba25e82d.png - Plastic,Craft,Prototyping,Product Design,Opensource

    2-186ba25e82d.png - Plastic,Craft,Prototyping,Product Design,Opensource
  3. 3

    Thin out the end sides of the plastic board

    Thin the edges of the plastic board using a portable sander for a better fit in the subsequent step.

    3-186baadba45.png - Plastic,Craft,Prototyping,Product Design,Opensource

    3-186baadba45.png - Plastic,Craft,Prototyping,Product Design,Opensource
  4. 4

    Bend it

    Now bend it with care. Secure it using a rope.

    4a-186ba278eb1.png - Plastic,Craft,Prototyping,Product Design,Opensource
    4b-186ba27a02a.png - Plastic,Craft,Prototyping,Product Design,Opensource

    4a-186ba278eb1.png - Plastic,Craft,Prototyping,Product Design,Opensource
    4b-186ba27a02a.png - Plastic,Craft,Prototyping,Product Design,Opensource
  5. 5

    Weld the end pieces of plastic

    Instructions for Soldering Plastic

    Using a soldering iron, securely weld the plastic end pieces together. Ensure the bond is strong.

    5a-186ba28457e.png - Plastic,Craft,Prototyping,Product Design,Opensource
    5b-186ba28645a.png - Plastic,Craft,Prototyping,Product Design,Opensource

    5a-186ba28457e.png - Plastic,Craft,Prototyping,Product Design,Opensource
    5b-186ba28645a.png - Plastic,Craft,Prototyping,Product Design,Opensource
  6. 6

    Smooth out the welded part

    To achieve an even surface, use the sanding machine to smooth the welded section.

    6-186ba28d230.png - Plastic,Craft,Prototyping,Product Design,Opensource

    6-186ba28d230.png - Plastic,Craft,Prototyping,Product Design,Opensource
  7. 7

    Done!

    Completed Lampshade

    Your lampshade is finished.

    7-186ba29536d.png - Plastic,Craft,Prototyping,Product Design,Opensource

    7-186ba29536d.png - Plastic,Craft,Prototyping,Product Design,Opensource

To bend a plastic sheet using kerfing-inspired techniques as described, the following tools and materials are required:

Tools

Hardware

No specific software is needed for this method.

Articles

  • https://polysynthesis.au/blog-plastic-sheet-bending/
  • https://polysynthesis.au/bent-plastic/
  • https://www.justpolycarbonate.com/post/bending-polycarbonate-everything-you-need-to-know
  • https://exceliteplas.com/fabrication/bending-plastic/
  • https://www.caamatech.com/post/arcylic-bend-guide
  • https://www.thesprucecrafts.com/bend-sheet-acrylic-plexiglass-with-tools-2366806
  • https://weetect.com/polycarbonate-bending/
  • https://www.beeplastic.com/blogs/plastic-insights/a-beginner-s-guide-to-bending-abs-plastic-sheets-and-rods

Papers

  • https://apps.dtic.mil/sti/tr/pdf/AD0847865.pdf
  • https://libstore.ugent.be/fulltxt/RUG01/003/014/851/RUG01-003014851_2021_0001_AC.pdf

YouTube

  • https://www.youtube.com/watch?v=ovqnIBQuezA
  • https://www.youtube.com/watch?v=t4JGlWyVDLs
  • https://www.youtube.com/watch?v=CIBRmBxTPCA

Opensource Designs

  • https://community.preciousplastic.com/library/bend-plastic-sheets
  • https://www.stirpad.com/news/stir-news/kuo-duo-lends-bendability-to-plastic-boards-through-the-kerf-plastic-series/
  • https://www.ucl.ac.uk/bartlett/architecture/kerf-sculpting
  • https://community.preciousplastic.com/library/bend-with-the-sheetpress
  • https://www.instructables.com/Laser-Cut-Ambient-Light-With-Kerf-Bends/