Assignment Week12
Composites





This week’s assignment is "Design and make a 3D mold (~ft2), and produce a fiber composite part in it”.
I tried to make motorcycle fuel tank that made with FRP.

Making 3D mold



First I make 3D data of tank using Rhinoceros.

Tank's shape has flat surface and curved surface.





Next, I put cuboid block data over tank's shape.

And, make female die's shape using boolean subtraction command of Rhinoceros.





Female die's data can download here.



Next, I challenged to make the "female die" that be made with MDF.

I used "123D Make" This software can translate 3D data to Press-fit construction.

We can download it here.

.

I import female die data and setting information.




123D Make can export eps data to make T2.5 MDF parts using laser cutter.

Laser cutter setting

MDF size : T2.5
Feed : 10mm/sec
Power : 30%

It can download here.

.

Press-fit construction have many many chinks. So I infill it with clay and stick aluminum sheets inside of female die.



Make FRP Parts



I make FRP parts using my mold.

FRP made by 2 kind of synthetic resin and glass fiber sheet.



Grass fiber

1. Cut fiber sheet to small rectangle shape like postcard size.

2. Mix 2 synthetic resin liquid as fixed rate.

I used polyester resin, and　curative agent.





3. Stick glass fiber and draw mixed resin.




4. Dry female die and resin.

5. Break female die, and scratch clay and aluminum sheets.




6. For finish, draw polyester putty on resin's surface, sand, and draw silver color.



Complete!!