Category: molding

Silicone overmolded vibrator – balls revisited

molded-quermolded-with-ueberh-querBuilding your own silicone molded vibrator becomes now easier. We already have presented 3d printed forms for building your personal vibrator (massage wand, wireless charged vibrator). The vibrator uses the body interaction vibrator development board. The body interaction board has a Arduino compatible microcontroller, vibration strength control by motion, a vibration motor and a rechargeable battery.


balls_revisited_3_inlay_part_bWhat is new? The electronics including battery are in the base of the vibrator. We developed a 3d printed enclosure for the electronics. This has several benefits: The assembling of the electronics and the molding itself is easier as everything is fixed within the enclosure. And it is more safe as the enclosure shields the electronics from the environment (and vice versa). In addition we used a different charging module from Seeed Studio. The input voltage is only 5V. Now you can connect the charging module with a USB connector and don’t need another power supply. (Look here for an explanation of wireless charging sender and receiver.)


Another improvement is the placing of the vibration motor. The vibration motor can now be placed in the center of the vibrator and it different heights. Just were you need the power.

balls_revisited_3_inlay_part_aFinally the mounting is improved. The mounting holds the enclosure when it is inserted into the form.

balls_revisited_3_finalThe mounting (together with the enclosure with the electronics) is inserted into the form. The form consists of two parts which must be fastened together by tinker wire. It is a variation of the ball theme.

We present a step by step procedure for tinkering the vibrator. You need:

  • 3d printed form (molding form, 2 parts)
  • 3d printed enclosure
  • 3d printed mounting
  • body interaction vibrator development board
  • silicone with a high shore A value (eg. shore A 45 which is quiet hard but still flexible), approx. 100 ml
  • wireless charging module eg. from Seeed studio
  • soldering station, (hot) glue

Step by step procedure:

A. Print out all forms. You can download the forms from Thingiverse.


B. Connect the wireless charging module to the body interaction vibrator development board.

B.1 You have to solder a wire connecting (-) on the wireless charging module and GND on the body interaction board.

B.2 Now comes the tricky part. You have to connect (+) from the charging module with the body interaction board. Solder a wire at (+) of the charging module. But where do you solder the wire on the body interaction board? Unfortunately the wireless charging option was not taken into consideration during the development of the board. So there is no appropriate connection on the board.

circuitThe best solution is to unsolder the USB connector and connect to + of the USB connection. The easiest way to unsolder the surface mounted USB connector is done with a hot air soldering station.  Alternatively you can solder the wire directly to the MAX1555 module – this solution is presented here. In any case: Be careful not to break the tiny pads connecting pcb and USB connector.

B.3 Connect the sender module with a 5V power supply. You can use a USB cable, dismantle the cable and connect the black and red wires.


C. Place the receiver charging coil on top of the enclosure. The diameter of the top side is a bit larger than the diameter of the bottom side. Use some glue to fix the coil. Don’t fix the mounting now. It is easier to do it later (step E).


D. Put the electronics into the enclosure: Begin with the body interaction board. The RFM12b is quite large so place it at an outer position. Then insert carefully the LiPo battery. Don’t force it! The plugs for the battery and the motor could break. If you have done so insert the tiny wireless charging receiver board. At the end fix the wires of the vibration motor in the middle of the enclosure.

E. Connect the mounting with the enclosure. There are 2 holes provided where the mounting fits into the enclosure. Use some glue to stick together both parts. (see picture above step C).



F. Put together both parts of the molding form. Use tinkering wire to attach both parts tight together. Then insert the enclosure into the form. Check the wireless charging function. The yellow LED must be on when you place the charging coil over the receiver coil.


G. Now poor silicone into the molding. We use Shore A 45 silicone which is rather hard. The silicone has to dry for some hours or days. Read the instructions of your silicone provider.


H. When the silicone is hard, you can remove the tinkering wire. Then carefully remove the form.


I. Remove the overhang.


J. Test the wireless charging. The orange LED must be on when both coils are near together.

molded-bottom IMG_20160303_184830

K. Remove the mounting.


Design your own forms using Tinkercad. Start now and share!

Old versions of the enclosure:Enclosure & mounting togther, Enclosure , Mounting

Download the STL files for 3d printing from Thingiverse.

Update 2016/03/12: Added image of circuits showing where to solder the wireless charging module.

Update 2016/04/05 redesign of mounting and enclosure due to different versions of the wireless charging receiver coil

Wireless battery charging of the body interaction vibrator development board

bisiliconeformfilledreadybigsiliconereadyvogel2One major Problem oft DIY electronic sex toys (or massage wands) are the need to charge the batteries. Usually the batteries are charged via the USB connector. This means that there is a physical connection between the sex toy and the USB connector, making it impossible to mold the whole sex toy with eg. silicone.




The solution is to use a wireless charging module (eg. this module from Seeedstudio). It comes in two parts: The sender (IN) and the receiver (OUT). Both are connected with a coil. If you place the two coils close together, the sender coils induces power in the receiver coil. Though you can share the batteries wireless. The receiver could be molded, separating the electronics, batteries, connectors etc. from the environment. The result is a form with a smooth surface enabling secure usage as a sex toy.




bigsiliconeready crossmeovedWe have made an easy DIY solution based on the body interaction vibrator development board, wireless charging module and a 3d printed silicone molding form.










big wireless part a

Part A: The molding form consists of two parts.


3d print form A

Step 1: The form comes in 2 parts. Print both parts of the form. The STL file is called part A. After printing polish the inner part of the form as well as the surface between the two sides.







big wireless part bStep 2: Now print out part B. It is used to fasten the board, battery, receiver coil and receiver board.







verkabelung seeedwirelssechargingStep 3: Connect the + pad of the wireless charging receiver board with the pin marked + of the vibrator development board (that’s pin 1 of the MAX1555 battery charging IC). Connect – of the receiver with the GND pad of the vibrator development board. You need two short wires and have to solder them at the two boards.





wiresStep 4: Now wind up the wires connecting the board with the battery and the vibration motor. (The connection to the receiver board is not shown on the image.)








battery and board installedbattery and board installed 2Step 5: Now attach the coil on the shorter “cross” of part B with some glue. There must be space between the coil and the outer longer cross. Then attach the board, battery and vibration motor as shown in the pictures. you can use some glue to fix these parts. Be sure to set the switch to the ON position.






The receiver board can be placed within the coil. It’s the small long board in the middle.









boardandbattery in half-formStep 6: Fix part B (with board, coil etc.) at part A. Be sure that there is enough space between them (min. 5mm).











form and electronics inserted 1form and electronics inserted vogelansichtfilles form from topStep 7: Now attach the second part of part A. Use some tinkering wire. Double check: There must be space between Part A and part B. And there must be space between the coil and the upper edge of form A as the coil must be molded by the silicone.






aftermolding wireless formStep 8: Now pour silicone into the form. Use silicone with a high Shore A value. The higher the Shore A value is the higher is the firmness of the silicone form. We have used silicone with Shore A 45. You need about 90 ml silicone.











bigsiliconeready removedStep 9: After the silicone gets hard, remove the tinkering wires and softly remove the form A. Remove overhanging part.







bigsiliconeready crossmeovedStep 10: Now you can remove the outer cross of part B.











bigsiliconereadyvogel1That’s it. It takes about half an hour (without printing). Before using check carefully that the silicone is solid. Even if you skew the silicone form you should not be able to feel the edges of the vibrator development board. Otherwise there is the danger to get hurt. Use it as a massage toy on your own risk. For charging the batteries place the molded coil over the sender coil. The yellow charging LED should go on.

The next development step is a battery charging station!






Download 3d printing files from Thingiverse

Modify and construct your own with the online 3d modelling software Tinkercad: Form A, Form B


Molding a silicone case for the BI1 board with a 3d printed form

As alternative to the 3d printed form a flexible form made with silicone could improve the handling of the body interaction board (BI1) for certain applications. The vibration is more comfortable and less noisy compared to other cases. If you want to do it on your own follow this how-to.

Silicone molded BI1

Silicone molded BI1: vibration motor (top), RF12b (bottom)


silicone molded BI1 board – vibration motor (top), LiPo (bottom)



Some adult toys are made of silicone or at least are coated with silicone. Silicone cases are easy to clean.








We have constructed a 3D printed form where we will fill in the silicone. The form comes in two parts that have to be fixed to one another by tinkering wire. In addition the board has to be hooked to the form. For this we use a USB connector which is plugged in the USB port of the board. Then the USB connector is fastened to the form.

Form for molding

Form for molding

USB connector holding BI1 board is fastened with tinkering wire

USB connector holding BI1 board is fastened with tinkering wire













Use a silicone which will become solid after moulding. This property of silicone is indicated by the shore A value. Silcone with a low value is flexible. We use silicone with shore A 43.

Molding form with USB connector and 2 component silicone shore a 43

Molding form with USB connector and 2 component silicone shore a 43

molded BI 1 and 3d printed  form

molded BI1 and 3d printed form





Do you want to try it on your own? Follow this how-to and tell us your experience.

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