Static Flock Applicator

A static flock applicator gives your 3d prints a warm fuzzy feeling. It can also be used on model dioramas for a realistic grass look. I call mine the Zeus Zapper. Like Zeus it does spark and can give little tingly shocks. Don't let that put you off. I was an idiot and paid no attention to things, important things, like personal safety.

Ion generator - Something that looks like this and can be brought of the Internet

Some different coloured hook up wire. I used 22AWG and 28AWG silicon wire. This is sooooo much nicer than the PVC coated wire.

A sandwich for lunch

One of those power socket things that a 12V transformer plugs into

A hopper - to put the flocking powder in

Some mesh for the flocking powder to collect a charge as it passes through. I brought a cheap noodle strainer from the local cheap shop that sells cheap things cheaply. Then I butchered it.

Terminal blocks - although you could solder a spiders web of wires together to make the circuit.

Switches - A momentary switch. That's the one that only turns on when you press it and turns off when released. It doesn't stay on without help. And a 12Volt LED switch.

LEDs and resistors to match - I know there is a formular that matches LEDs to the correct resistor but I've never used it and 470K ohms has worked for me in the past. Never had a problem. Not broken so I'm not bothered about fixing it.

Alligator clip

Flocking powder or model railway flock. The stuff I used is for finger nails and is sprinkled over them for fuzzy finger nails. I learnt something new when I looked for it. Who would ever have thought. Fuzzy finger nails.

Why have two switches? I wanted double safety. The LED switch turns on the applicator unit. The momentary switch starts the current and lets rip a flow of ions which charges the flocking powder in the hopper as it passes through the mesh. This then is attracted to the work piece which is connected to the negative line. The blue LEDs show the ionization process is happening. Blue LEDs because, as everyone knows, Zeus has blue eyes.

What I wanted to see was a small spark from the end of the ion generator wire to the negative line, a working on/off LED switch and blue eyes. Can you see the little spark? So cute. Take care at this stage and check the circuit and that there aren't shorts or mistake contacts. The shocks are annoying and if you've got a soldering iron in your hand at the time, expect a burnt leg when you drop it. Remember, only you can stop yourself from being electrocuted.

The hopper is a jar where the flocking powder is kept. On the bottom of hopper is a mesh screen that's connected to the ion generator. I made my hopper with a fine mesh as the flocking powder was very fine but I can make another hopper that's larger and has a course mesh for flocking that's used on model railways to make grass that stands upright as real grass should. Thread bare multi core wire through the mesh and twist it together. Soldering is going to be a problem as solder don't stick too well to stainless steel. Just make sure the wire has good contact. Wear a mask when flocking. The powder is fine and beathing it may be a problem.

I 3d printed a hopper holder and a head of Zeus. I didn't have to. It was Covid lock down at the time so I had time on my hands. The outside container holding the bits together is up to you. A plastic jar can be used. Some PVC pipe. The applicator is in two parts. The main equipment is under Zeus. The hopper and switch are in the hand held part and a platted cable links the two parts. Some 3mm acrylic was laser cut.

The assembled Static Flock Applicator is ready for use. Fill the hopper with flock and have everything ready to go. Now. Get the piece of work you want flocked and spray paint it with a slow setting enamel paint. Then clip the black negative wire to the piece making sure there is a good connection. I screw a screw into the back of things and attach the negative wire to that. Start flocking. Hold the hopper over work about a couple of centimeters above. Gentle taps let the flocking powder fall through the mesh and pick up a charge. The flock is attracted to the work and will fall standing upright and not in clumps. The colour choice of the base paint, used to adhere the flock, will effect the final outcome colour. I used black paint with white flocking powder and this gave a grey, bone look. Spray paint gives a better, smoother finish than spray adhesive. This was with one spay coat and flock. The 3d print layer lines are just visible. Try a couple of base coats. The local makerspace has a wall where examples of work are displayed.