My CBC friends came to me with a creative idea for their Founding Members wall, what if all 150 names were engraved on bocce balls that appeared to “extrude” right out of a cinder block wall?
After plenty of research and development, I brought their vision to life. Using the GF Pro, I cut and engraved 4.15” flat acrylic discs, then heated each one to 300°F to thermoform them into official regulation–size bocce balls. With a touch of acrylic paint, spray foam, and VHB tape, everything was securely installed.
Wow. … That was really a labor of love. Zooming in on your picture I was able to see how much work you put into your engraving. I am sure that everyone will be pleased.
It took a lot of trial and error to figure out the right amount of material so that when I pressed the acrylic sheet into the mold, it wouldn’t ripple from excess plastic. The red disc photo shows my very first attempt 4.5” was far too much material. On the bright side, I learned that you can easily reheat the acrylic and try again.
Welcome to the forum! Great way to introduce yourself! That wall looks absolutely fabulous and will certainly be enjoyed by everyone there for many, many years!
This is really cool. So, you engraved first, and then molded the acrylic into the shape? It’s remarkable that there doesn’t appear to be distortion. It looks like you added paint to the engraved areas. Is that correct?
Yes engraved first then molded them, the discs with the star logo were distorted slightly once it got to the edge but not v noticeable. Filled it with acrylic paint and used Isopropyl alcohol to remove the excess.
Amazing job and all the bocci balls are so consistent in shape. I wonder if the plaster of paris mold was the secret. Did it support the acrylic better and absorb excess heat that made mine and others slump a bit? Great result, thanks for the share. Please come back again with your other projects.
I think that was the trick. However, I was only able to use the mold for a short time because the heat started to break down the plaster. I didn’t let it fully cool in the mold—just about a minute—then ran it under cold water to help it set.
