Objective:

The objective of this Instructable is to create a usable phone case from carbon fiber. Carbon fiber is a great material for a phone case because it is not only lightweight but also strong due to it being a composite material. Follow the steps below and by the end you will have a usable phone case.

Hazards:

When using epoxy, it is very important to avoid getting the epoxy on yourself or any objects around you because it will harden and not come off easily. Carbon fiber also can irritate the skin, so avoid touching it bare handed and do not rub your eyes after coming in contact with carbon fiber. A high speed dremel will also be used; so make sure you are careful when using equipment that could potentially hurt you. It is recommended that you wear vinyl gloves and safety googles at all times throughout this procedure.

Step 1: Prepare the Materials and Work Space

Materials

Phone Mold

Phone Case
Plaster of Paris
Water
Wooden Tongue Depressor
16 oz Cup
3 oz Dixie Cups
Glad "Press n' Seal"
Saran Wrap
Vinyl Gloves
Safety Goggles

Carbon Fiber Case

Finished Plaster Phone Mold
Carbon Fiber Sheet
Carbon Fiber Epoxy
Foam Brush
Vinyl Gloves
Masking Tape
Vacuum Bag and Nozzle
Vacuum Pump
Vacuum Hose
Saran Wrap
Wax Paper
High Speed Dremel

Work space

Cut out a large square of saran wrap (2'x2')
Tape down edges using masking tape to work space

This is so epoxy doesn't get everywhere

Step 2: Phone Case

It is now time for you to select which phone case of yours you would like to make a plaster mold out of. To insure that the mold effectively represents your case and the plaster doesn't ruin it.

Clean your preexisting mold
Place Glad "Press n' Seal" down into the case, ensuring the Glad touches every part of the inside of the case

Step 3: Pour Plaster Into Phone Case

Once you have made sure that the Glad "Press n' Seal" is smoothly inside of the phone case:

Mix the correct proportions of Plaster of Paris with Water (ratio should be 2 parts plaster to 1 part water)
Use the 3 oz cups to measure out the correct volumetric ratios
Add the parts to the 16 oz cup
Stir with wooden tongue depressor until the consistency of the plaster is similar to pancake batter
Pour the liquid plaster into the phone case
Let this sit for 24 hours so it will be completely hardened

Step 4: Remove Phone Mold

Remove the phone mold from the phone case very carefully without cracking the plaster
smooth over rough edges by dipping the wooden tongue depressor in water and working it around the mold

Step 5: Carbon Fiber Assembly

Cutout a sheet of wax paper with 1/2 inch larger perimeter
Cutout a sheet of carbon fiber with the same dimensions as wax paper
Secure wax paper around the mold using masking tape, must apply tape to wax paper because it won't stick to the plaster
Carefully wrap carbon fiber around the outer layer of the wax paper, making edges nice and smooth. Make sure you don't start unraveling the carbon fiber strands.
Tape down Carbon fiber to the wax/mold but don't apply tape anywhere that will show in your final phone case or else you wont be able to remove it

Step 6: Epoxy Application

Thoroughly mix the epoxy and hardener with correct ratios provided by manufacturer using wooden tongue depressor
Once epoxy/hardener is mixed, use foam paint brush to begin applying epoxy to the carbon fiber
Make sure you apply the epoxy thoroughly and with multiple layers; however, don't let it layer unevenly
Leave on a flipped over Dixie Cup until it's time to vacuum the phone cases