The case for the wand was molded in plastic.
First a mold was made for the case. One of the wand circuits was covered in clay (we used "Sculpey") and the clay massaged into a shape that we liked (Curtis came up with the shape). Then the whole thing was covered in silicone rubber (Tap Silicone RTV Mold-Making System). The resulting mold was cut in half and the clay-covered wand removed.
To make each wand, a wand circuit board (complete with LEDs and batteries) was placed into the mold and then liquid plastic (Tap Quik-Cast Polyerethane) poured in around it. The plastic cures in about 10-15 minutes, and out comes a wand. The resulting white plastic wand is painted brown.
The mold was made in such a way that 6 leads were left exposed (J2 in the schematic). This allowed us to program the final code and time of day into the wand after it was encased in plastic.
This file Copyright (C) 2006 by Nathan (Acorn) Pooley
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Gadgets of Justice Unlimited
File created by Acorn on Sat Sep 16, 2006