Workshop: Making New Plastic Parts
The curtains on our camper van were in need of some TLC, but spare parts weren’t easily available because the vehicle is over 16 years old. I managed to avoid searching around scrap yards by fabricating my own replacement curtain hooks. I made a simple mold by pushing an original curtain hook into warm polymorph (a trade name for polycaprolactone) and then waiting for it to cool.
I sprayed silicone oil over the mold to act as a release agent, and then pushed warm polymorph into the mold with my thumb. I then cooled the hot plastic using canned air, and removed the newly formed curtain hook from the mold. I removed excess plastic with a scalpel and smoothed any rough areas with a soldering iron turned to its lowest setting.
The parts are not as glossy and smooth as the originals, but they do their job perfectly. I could have used a two part mold and cast the hooks out of casting resin, but for simple functionality this technique worked well.