Group assignment: Review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them
Individual assignment: Design a 3D mold around the stock and tooling that you'll be using, machine it, and use it to cast parts
Group Assignment:
This week group assignment is to review the datasheets of the materials we are using in making mold and cast. Below we are sharing some important points after reviewing safety datasheets of Mold Max 60 for molding and Smooth-Cast 305 for casting materials.
Mold Max 60 Safety DataSheet Review:
Mold Max® 60
Product/Chemical Name: Mold Max® 60 Part A:
Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
Inhalation - Remove source(s) of contamination and move victim to fresh air.
Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
After first aid, get appropriate in-plant, paramedic, or community medical support.
Flash Point - 300 °F
Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
Storage Requirements - Store in cool dry, well-ventilated area
Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
Toxicological Information:
Eye Effects: Irritation
Skin Effects: Irritation
Carcinogenicity: None Determined
Mutagenicity: None Determined
Teratogenicity: None Determined
Product/Chemical Name: Mold Max® 60 Part B:
Hazards Identification
Harmful if swallowed.
Irritating to eyes, respiratory system and skin.
Harmful to aquatic organisms may cause long term adverse effects in the aquatic
environment.
Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
After first aid, get appropriate in-plant, paramedic, or community medical support.
Flash Point - 150 °F
Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
Storage Requirements - Store in cool dry, well-ventilated area
Protective Clothing/Equipment - Wear chemically protective gloves and aprons to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
Toxicological Information:
Eye Effects: Irritation
Skin Effects: Irritation
Carcinogenicity: None Determined
Mutagenicity: None Determined
Teratogenicity: None Determined
Smooth-Cast 300 Series Safety DataSheet Review:
Smooth-Cast 305
Product/Chemical Name: Smooth-Cast 305 Part A:
Hazards Identification
Harmful by inhalation.
Irritating to eyes, respiratory system and skin.
Limited evidence of a carcinogenic effect
Harmful; danger of serious damage to health by prolonged exposure through inhalation environment.
Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
After first aid, get appropriate in-plant, paramedic, or community medical support.
Flash Point - 262 °F
Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
Storage Requirements - Store in cool dry, well-ventilated area
Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
Inhalation - Remove source(s) of contamination and move victim to fresh air.
Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
After first aid, get appropriate in-plant, paramedic, or community medical support.
Flash Point - 262 °F
Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
Storage Requirements - Store in cool dry, well-ventilated area
Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
Toxicological Information:
Acute Inhalation Effects: None Established
Acute Oral Effects: None Established
Reproductive Toxicity: None Established
Mutagenicity: None Established
Teratogenicity: None Established
Sensitization: None Established
Individual Assignment:
1. Designing the Mold
This week sounds quite interesting because I have been looking this kind of work at many places but it was first time i myself doing it :D
First I need to thought about a design and after thinking for some time I remembered the Logo very famous among the people watching Sci-Fi movies. This was from the movie "Batman Vs Superman: Dawn of Justice". For that I took two logos and combined them to make one model. The model as an image looked like the picture given below:
Image of the model
For making .svg file and then .stl file, I followed the below mentioned steps:
Create the design in Adobe Photoshop
Open it in Inkscape
Save it as a .svg file
Import .svg file to Rhino
Extrude the curves of model and make it solid
Make boundaries around your model, having height twice or greater than the height of your model
Make sure that the boundaries must have angle greater than "90 Degrees"
Making Model using Photoshop and Inkscape
After making the .svg file I opened it in Rhino and extruded the curves and made the boundaries as shown below:
Making the model in Rhino
2. Using Modela Player 4
Using .stl files from Rhino in Rolland Modela Player 4, we will generate .prn files for milling through Rolland SRM-20. Following steps will help you in using this software, you can also get help from the video embedded below:
Open .stl file in Modela Player 4
Select the machine that you have in your Lab
Set the Origin
Set the margin from boundary walls by selecting Manualoption
Start a new process, named Roughing
Select Z at the top axis
Select the tool width, 3mm(for roughing)
Set the cutting area by choosing the "Partial" option
Set the "Contour Lines" to Up Cut
Set the "XY Speed" to 24mm/sec
Rename the process accordingly and press the Finish button
Once completed, you can view the toolpath as well by clicking on the button at bottom right
Similiarly add another process for Finishing. But change the tool size to 1mm, Scan lines to X+Y and XY speed to 14mm/sec
Finally press the "Cut" button, now here you may either give the file directly to machine or you can save them as .prn files for later use.
All the above mentioned steps can be further clarified by watching the video below:
3. Milling the mold
After the .prn files were generated I used them in Rolland SRM-20 and started milling the mold from Machinable Wax
Steps performed for using the Rolland SRM-20 were same as mentioned in Week4
During the milling picture
Although in first attempt of milling, the mold was quite good but the height of model was not enough, it was very small as shown in the picture below
First mold after milling with very small model height
Inorder to correct this mistake, I increased the height of my model and started milling again. The results were satisfactory after the second attempt and can be seen below:
After Roughing in second attempt
After Finishing in second attempt
4. Making the mold
Now was the time to take some measurements, we will first add water to the mold so that we get to know how much materials we will require to add and make the silicon mold. For that i used the steps shown in the GIF below:
Steps for taking measurement using water
Initially I used Smooth-On SORTA-Clear 37, Silicone Mold Rubber to make the mold. Before using it I went throught the paper available inside to see how much ratios of both materials need to be added.
Smooth-On Silicone Mold Rubber
Smooth-On Silicone Mold Rubber
From the instructions given on the paper, I took 100% of part A (Total weight of water measured) and 10% of part B.
Measuring the materials, part A and part B
After adding both the parts of material, I started mixing them for 3 to 4 minutes. Then i poured the material in machinable wax mold and filled it completely. The image below shows many bubbles in the silicon material, I was unable to remove them since we couldn't create a proper vacuum mechanism for our lab.
Mold filled with Rubber Silicon
Then I left the mold for curing, and when I went back to lab after two days to see how is it? But it had not cured propperly. So I removed the rubber silicon from the mold and proceed for making mold using another material.
Removing Rubber Silicon
A possible reason for the problem occured with Sorta-clear can be the inappropriate material ratio used. While making the mixture we went through the instruction sheet available inside. On that sheet there were different ratios mentioned, So instead of selecting 1A:1B I mistakenly selected the ratio of 100A:10B, due to which the mold didn't cured properly even after so many days.
A possible reason of mistake while making the Sorta-clear mold
Using Mold Max 60
After getting failed in first attempt, now I decided to make the mold using Mold Max 60. The mold made out of this material can also be used for metal casting. It means that I can cast it using the metal available in the lab as well.
Mold Max 60
Using almost same steps as before, this time I took 100% part A material and 3% part B material and mixed them for 6 to 7 minutes and poured the material into the mold and filled the mold.
Mold Max 60 material in the Wax mold
After filling the Wax mold with Mold Max 60, I left it for curing and took the mold out on next day which can be seen below:
Mold made of Max 60
5. Casting
Now I was ready to make the cast of my model, for that I am using "Smooth-On Smooth-Cast 305".
Casting Material
Casting Material
Using the instructions written on the page available inside I made a mix of 1A:1B, which means both parts of material should be in equal proportion. 50% part A and 50% part B of the weight measured by pouring water inside the mold. After mixing it 1 to 2 minutes I filled the mold with it.
Make sure to mix and pour this solution while the fan is switched off, otherwise it will harden quickly.
Casting Material in mold
After a few failures and some hardwork, i was finally able to make a proper cast using the molds. The final casting result along with the mold are shown below:
Final Results
That's all for week10..
All the Files of Week 10 can be downloaded from Here.