Molding and casting

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3D design

The design I made for molding and casting is a cover for my USBtiny IS. I imported the PCB from Eagle to Fusion and drew the main components, since their 3D model was not available in my Eagle ligrary

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Then I designed a cover with in taking into account the dimensions of the pin headers and the USB connector

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Using boolean operations I got the Negative mold.

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The positive mold is obtained from the negative mold with a simple boolean.

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CAM settings

The first milling operation is adaptive clearing with a 5mm flat end thread

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The second milling operation is pocketing with a 3mm flat end thread

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The last milling operation is smoothing the edges with a 1mm ball nose, with a ramp pattern.

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Molding

Wax mold (positive)

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Silicon mold (negative)

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The edges of the wax mold were not smooth as expected. Perhaps the ramp smoothing was not the best setup, or the increment was to big