The following pictures show a step by step on how we made some of the joint parts in Polymorph plastic, our final intention is to model these pieces in 3D, and to print them out on a cheap DIY rapid prototyping machines like the Makerbot or Reprap. At this stage we chose to use Polymorph as it is much faster to obtain a proof of concept, which will allow us to save precious time once we get modeling the pieces in 3D. Polymorph is a thermo plastic, it comes in granules and melts into a moldable paste at just 62`C.
1- The Polymorph granules.
2- Some handy tools to work with Polymorph.
3- After just a few minutes in hot water, the granules form a mouldable paste.
4- Polymorph ready to be moulded.
5- A handy trick to create pieces with an even thickness.
6 – By placing 2 sidebars with equal height when rolling the Polymorph into a flat sheet, the sheet gets an even thickness.
7- Once we obtain a flat sheet of Polymorph, we can take it to the next step, moulding the actual object.
8- Here we are making one of the pieces that will function as a connection between the servo motor and the acrylic tube. To make sure the tube will fit tight in the connection, we use tape to apply force on the Polymorph while it hardens.
9- To speed up the process of hardening the Polymorph, we place it in a freezer for just a few minutes.
10- Once the piece is hardened, excess bits can be sawn off with a normal saw.
11- A finished piece, this piece is one of the parts that connects the tube to the servo motor.
12- Another finished piece, this one is a little more complicated as its the middle joint that has to support a servo hanging in midair.
12b- Both pieces that form the middle joint.

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