When we last contacted the prolific prototyper [Eric Strebel], he was perfecting the design of the environmentally friendly wireless charger and turning his initial paper prototype into a version 2.0 particleboard with manufacturing issues in mind. At the end of the second video in this series, [Eric] is printing early versions of the form, and he will eventually use these versions to make a brass wire mesh mold for processing cardboard pulp. You know, some egg cartons are made of these things.

In the video below, it is time to build a pulp mold by creating three smaller molds and then connecting them into a horizontal mold. The result is a single piece, which is then folded into a charging rack, like an egg carton. [Eric] A brass screen is used here, but he said that copper is also a good choice.

After cutting the brass with scissors and knocking them flat, he used the 3D printed mold in the previous video to press them into the correct shape. Each of these three parts needs a frame, [Eric] made it with more brass wire mesh, then sewed it to the mold piece with loose wire mesh, and then fixed the joint with solder.

Since the weight of all water may deform the brass, [Erik] completed the mold by welding on a flat brass bar frame. Check out this great process below, and stay tuned for the next video, when [Eric] beats some cardboard and pulls out some eco-friendly chargers.

Does this seem too complicated? You can always skip the entire mesh mold and shape the cardboard scraps directly into 3D printed parts.

This is also a pretty good start for people who want to make small Faraday cages for RF products.

It is easier for me to take some thin steel and weld them together.

Well, I want to know if you can use solder paste on the connection...

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