How to Prototype - Syrofoam

This is the routine
I went through to make mu bamboo natural water purifying bottle prototype 1. It includes using the different tools.

This instructable will contain the simple and most basic routine when completing any styrofoam prototype. You will need the following;

- extruded styrofoam (the thickness depends on what you are prototyping)

- a coping saw

- a metal ruler

- a rounded file

- a rectangular file

- sand paper (different grits)

- pencil or pen

- a temple or stencil of what you were creating with any key dimensions

Cut your Styrofoam to the right height/depth making sure you have enough room to complete your prototype. Do this using a number of tools, for example a threat saw, a coping saw, a band saw or circular saw. There are also different tools which you can use but I just used a band saw and coping saw.

Use sand paper to neaten the surface up.

Use a glue stick/ blue tack to secure your template onto your surface. Make sure it is well stuck down and in the right place. It is probably best to use blue tack as you can always reposition it I its not in the best place.

Once the template is stuck onto the surface, use a coping saw to cut any unwanted pieces. Secure the Styrofoam into the vice as low as you can to decrease to possibility of the Styrofoam snapping. Also, make sure you cut nice and slow as if you go fast, you can damage the surface and it increases the possibility of making mistakes such as cutting the wrong part off.

Once the main shape of the design has been cut and any off cuts have been places to the side or thrown away, its time to shape the rest. This included me having to cut the angles to get a circular surface (to style it as if it were bamboo). This could be chamfers, joints, adding slots. Anything.

As soon as any unwanted material has been cut away, its time to use the files and sand paper. Secure your work into your work holding device securely before starting this step. Dont tighten your work holding device to much as it could possibly damage your work. Place the side of the file onto the place youre wanting to remove or neaten up. Use one hand to grasp the handle and the other to hold the opposite end of the file. This will make it easier to remove the material. Slowly begin to file away the material, making sure you only apply a little bit of pressure.

Once you have removed as much material as you want using the file, its time to create a smooth surface, sand paper is a great tool to keep in your workshop or tool box as you never know when it could come in handy. Slowly begin to sand away any un even parts while making sure you dont press on to hard. Make sure you sand the entire product. A belt sander or hand sander could be used but if you're using sand paper on a curved edge, use sand paper.

Congratulations, you can now apply this routine to all of your prototypes. Pleases like and comment if you have any more ideas of what I can design, make or complete an how to project on. Thank you