Recently, UCN, a user of DIY hot station Instructables, shared a very interesting method to teach you to use concrete and 3D printing to create a unique business card. To make such a business card, the first thing you need to do is to create a very thin concrete slab that needs to be strong enough and can withstand a certain amount of pressure so that it does not break instantly during the bending process. To achieve this, UCN from Singapore directly poured concrete into a 3D printing mold and hidden some 3D printed grids in the card as a reinforcing structure.
UCN relies mainly on FDM 3D printers to print PLA plastic into molds. Since the size of a general business card is 90 x 50 x 2.5 mm, and few people care about the print resolution, he prints with a 0.5 mm layer height and a 20% fill level. You can also explore the available 3D printing settings yourself.
The grid itself is also 3D printed. In this case, a thicker layer height may increase the power of the mesh (and more layers may mean inconsistent molten plastic and a weaker overall structure) than higher resolutions.
Once the mold is printed, it can be used to make business cards. He used a stable 4:3 grey water ratio and sprayed the silicone onto the 3D printing mold, then poured the concrete into the mold and placed it overnight (ensuring that the surface was flat and smooth).
The next day, he can remove the concrete business cards from the PLA plastic mold, which can be easily separated due to the presence of silicone lubricants.
After one more day, the load test experiment begins. The pure concrete sample card didn't have much surprise, and it was almost immediately damaged when it was only subjected to 160g. The corresponding 3D printed grid version did not appear to be chipped or bent before loading 595g. The result of the third test using a 3D printed square grid was 670g.
If you want to impress your business partners or friends with a concrete business card, try this project. According to UCN, he believes that using ABS may yield better results than PLA.
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