Evan and Katelyn 1

Currently Playing: THERMOFORMING 300° CORIAN (how to make salad servers)

Thermoforming (AKA heating then bending) corian has been something that interested us for a while and it was SO FUN!! It really paired well with CNC milling via our X-carve by Inventables, our sponsor. These salad servers definitely won’t be the last of this project type. Let us know what you want to see next! 👇 materials & links below! 👇 Our Sponsors Sign up for Inventables Easel here (https://goo.gl/o5GaTo), then enter the Easel Power Hour Challenge here (https://goo.gl/2B8oBb) Thanks Rockler for the support! Check out their awesome router table here http://www.rockler.com/power-tool-accessories/router-tables Check out ISOtunes, our fave hearing protection: https://amzn.to/2uf0cnC Patreon & Aftershow https://www.patreon.com/evanandkatelyn Merch https://shopevanandkatelyn.com/ Instagram http://instagram.com/evanandkatelyn @evanandkatelyn Twitch live streams https://www.twitch.tv/evanandkatelyn TOOLS / MATERIALS (affiliate) ■ Corian https://goo.gl/34we86 ■ X-carve https://goo.gl/dBvSAL ■ Carvey https://goo.gl/Vh5mSt ■ Fluke thermocouple https://amzn.to/2JG2rXD ■ Economy thermocouple https://amzn.to/2xUZduw ■ Drill http://amzn.to/2iB1fGV ■ Drill bits http://amzn.to/2pAW1yw ■ Power screwdriver http://amzn.to/2mOZiWV ■ Bit set http://amzn.to/2pPA4MS ■ File set https://amzn.to/2JAAW1A ■ Drill press http://amzn.to/2gNBrI8 ■ Belt sander http://amzn.to/2gNWIBx FILMING GEAR (affiliate) ■ Fujifilm X-T10 http://amzn.to/2pblgac (main camera) ■ 35mm F 1.4 lens http://amzn.to/2whwP0N (makes things look fancy) ■ Sony Cybershot DSC-RX100 V http://amzn.to/2DJTHJF (slow-mo camera) ■ Main tripod http://amzn.to/2whGqED ■ Pan head for tripod http://amzn.to/2fhX3wh ■ Lighting kit http://amzn.to/2vs5sDB ■ Wireless lav mics http://amzn.to/2BCqtKQ STAY UP TO DATE ■ Instagram http://instagram.com/evanandkatelyn @evanandkatelyn ■ Twitter https://twitter.com/EvanAndKatelyn ■ Pinterest https://www.pinterest.com/evanandkatelyn/ ■ Blog http://evanandkatelyn.com ■ Etsy http://etsy.com/shop/evanandkatelyn MUSIC Lowrider by Joakim Karud Nobodys perfect by David Cutter Walking boots by David Cutter Scratchy by David Cutter THANK YOU TOP PATREON SUPPORTERS! ■ Katelyn’s Mom ■ Brandon’s Bees https://goo.gl/XP93pp ■ Bruce A. Ulrich https://goo.gl/wqixxp ■ Kit Low ■ Infinite Craftsman https://goo.gl/hsj5S6 ■ Zach and Jazz https://goo.gl/bmqvxi ■ Corey Ward ■ Figments Made https://goo.gl/Yj28sV ■ Vincent Ferrari ■ Scooter’s Workbench https://goo.gl/sP7b9W ■ Corso Systems ■ Brooke Boen ■ Matt Baker ■ Jason Kaczmarsky ■ Cameron Dorsey ■ David Granz ■ Elliot Iddon ■ Maxine Denis ■ Francisco Peebles ■ OmSweetOhm https://goo.gl/5Ue3ka ■ George Partin ■ Making at Home https://goo.gl/HzRd2H ■ Southern Style DIY https://goo.gl/r5PL2c ■ James Allen ■ Kyle C Katelyn started the design in Illustrator. We exported a vector as an SVG to import into Easel. We fired up our Inventables X-Carve to cut out a precise and repeatable shape (so they match and we can make another easily if we need to in the future) We cut them out with a jigsaw and an ordinary wood blade. It’s almost impossible to remove all the tabs completely cleanly though, so we cleaned up and rounded all the outer edges on our Rockler router table. It’s all decked out and every time we use it we really appreciate having it, especially compared to our old palm router. We finished up the shape by filing inner tabs and doing some hand sanding Once the shape was finalized it was time for some thermoforming (bending while hot)! We ran some tests before bending the final corian though. We embedded one thermocouple inside the corian and taped one to the outside. By the time they were at their final temperature (300 degrees F) the difference between the two was negligible. If you’re going to do this yourself and you don’t have access to a thermocouple, Dupont, the maker of Corian has this handy guide on what to heat your temperature up to for what time and thickness and it should get you to the right place: https://goo.gl/hKzzYJ We then made a form to shape the corian to. We held up some wooden salad servers we had as a guide and then matched their curve using some scrap wood and flashing. The first thermoforming went really well but we didn’t remove the thermocouple during the thermoforming and it actually indented the corian!! For the second thermoforming operation we removed the thermocouple and it was PERFECT! Remember: hold it in place till the temperature drops to 180 degrees F. We wanted to add little wooden dowels so the salad servers didn’t fall into our salad bowl. We drilled out a hole for the dowel, drilling in part way from each side we we didn’t chip the corian as it exited the hole. We rounded the edges of our walnut dowels on the belt sander, oiled them up, and hammered them into place! Lastly we did some final shaping to the salad servers on the belt sander and with some hand sanding to add a nice little taper.