Nuka Cola Bottle Caps

Model by Christopher Maddalena: https://www.prusaprinters.org/prints/49431-nuka-cola-caps

As a fan of the Fallout universe, I created this model to accompany my Pip Boy replicas–and to experiment with several finishing techniques discussed in the book.

Models like this exist, but many of them are thick or completely solid because real bottle caps are very thin. A real bottle cap is ~.22mm thick. To create the most accurate model possible, I researched bottle cap manufacturing. The Fallout universe is steeped in 1950’s science fiction and aesthetic. Prior to the mid-1960’s, caps had 24 aliases or ridges along the edge and were 6.75mm tall. I used those measurements instead of the modern 5.97mm bottle cap with its 21 ridges.

The resulting 3D model is delicate. They print best with a 0.25mm nozzle and 0.1mm layer height. The printed model is only a few layers thick. The caps are so light it takes little effort to heat and deform them. I used a heat gun to bend, crush, twist, dent, and smash the caps to create much more convincing post-apocalyptic currency.

Once deformed, I used CA glue, baby powder, and baking soda to fill layer lines inside of the caps and reinforce the thin top layers. I painted them with a layer of Alclad II Polished Aluminum lacquer and then red and white acrylics from Vallejo. I used masking fluid and steel wool to create chipped paint and worn edges. Each cap was finished with a paint wash using heavy wash acrylics.