Hello again,
Now, let's explain how I assemble the badges!
with text and pics, next message will be a video I shoot from the best of my poor video abilities.
Alright, so, after we have printed the badges and photos (this is already a long part, there is a lot of printing tests and colors/contrast adjustments), after we have cut the badges and photos, cut the corners of the photos like the screen used badge, glued the front and back of the badges together, cut the amberlith X as shown in the video on the previous page, we now need to assemble all of this together and laminate it!
first, we need to peel off the amberlith from its backing material. YES, like most of us know, there is a backing to the amberlith, it is very rigid and thick. the amberlith itself is extremely thin.
I use an Xacto knife for this, carefully, for both top edges and carefull peel off each side, especially carefull where they join as this is where they will tear off, as seen on the right when only peeling off from one corner:
look how thin and flimsy that thing is compared to the backing:
alright, now we need to carefully apply this to the paper badge and position it to the borders of the printed black, then apply some sticky glue to the back of the photo and carefully position it to hold the amberlith for the next step:
another glue step, I'm applying some Cleopatra glue under each corner of the amberlith, this allows the amberlith to stick momentarily to the paper and have a clean result for the next steps:
after this, the badge is put under of pile of books for a moment while I do those steps on other badges. When I have 6 of those done, I take the first one from under the books and cut the borders to the proper size, following the white crosses I have on the print. When this is done, I cut my round corners.
I'm not using a fancy steel machine, it's a cheap plastic thingy, but it has served me well for more than 100 badges already, and... well this one has the right corner radius at least. The top right corner on the original badge is also not cut all the way and is slightly smaller, so I'm matching this as well:
I have the refs printed next to me at all time, here is the new cut badge on top of the ref:
after this is done, the badge needs to be placed into its laminating plastic sleeve. The sleeve is already cut to the right side with proper round corners. This is how they did the original badges, you can see the badge wasn't carefully positioned into the sleeve and it is off-centered. So, i'm matching this too
(the plastic sleeve is very hard to see on the print, sorry)
Now, we laminate it. Again, I only have a cheapo machine, but it works spendidly and gives a clean result without big traces on the badge. I'm heating up the machine, running the badge from the closed short side of the sleeve first, then turn it 90° and run it again for a perfect closure all around.
and here is the result (those are obviously bad photos for now and the printed ref doesn't show all the details either):
alright, I'm going to try and post a full video next regardless of how I hate doing this!
I hope this gave some nice insights already on the process and you guys are enjoying it
cheers all