To make (almost) anything

About Me Assignments Final Project Fab lab 2019
Wildcard Week
Individual Assignment

read the safety data sheet (SDS) and technical data sheet (TDS)
for the resins that you're using
design and fabricate a 3D mold (~ft2)
and produce a fiber
composite part in it,with resin infusion and compaction

Group Assignment

produce test coupons for your composite fabrication process(es)

Individual Assignment

Reading Datasheet

I extract some important points from both Safety and Technical datasheets of Epoxy Solution we are using to complete oure this week task:

Part A

Here are some safety measures and warnings before using this material:

Part B

here are some safety measures and warnings before using this material:

Important Points from Technical Datasheets

What are Composites?

Basically, composites are the combination of some components having different physical and chemical properties, which combine to make a composite , which is stronger than the individual elements.Composites can be natural or synthetic. Wood, a natural composite, is a combination of cellulose or wood fibers and a substance called lignin. To make a composite you need four things:

  1. Mold or internal structure
  2. Fiber based material to combine with resin
  3. Resin
  4. Force or pressure to compress the composite as it cures
Designing 3d Model

I design a boat in this week for. I used SolidWorks to design my model and below I mentioned steps:

In start I select TOP plane from solidworks and draw line on it and assign dimensions to the line.

After that I select centerline and assign dimensions to that line

The I Used center 3Point ARC for curve

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Design In solidworks

After that I used Right plane for the edge and draw a rectangle on it .

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Draw Rectanle

After that I used Top plane and used 3point Arc for curve after applying tis the design looks like this

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Draw Curve

after that I applied profiling

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Profiling

After some steps The preview Looks like this

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Preview

In last I save file as STL to import in vcarve softare.

For this week assignments we are using High Density Foam which has thickness of 50mm. For milling high density foam we are using Shopbot (to understand how to work with Shopbot

VCarve Pro is used to generate G-Code for Shopbot

The steps to generate G-Code mentioned below:

First open VCarve and click on File > Import... and select Import COmponent/ 3D Model ... in a window select .STL file which we made in designing part

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Window Pop Up

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Design In vcarve

Now click on toolpath and select Rough Machining Toolpath we are using 0.5 inch End Mill drill bit, but it was not present in Tool database so we create New database, settings are shown in picture

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Tool For Roughing

Finisihing process is same the bit database is not present so we make with Ball Nose inch diameter other settings are shown in picture

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Tool For Finishing

Preview Of Roughing

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Tool For Finishing

Previwe Of All design

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Preview Of Design

Toolpaths are given to machine for further process and here are the some results

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Tool Change

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Setting XYZ

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Finishing

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Final Result

Fabric and Composites

I am using double layer of fabric in my assignment, it makes the surface more hard. The fabric are in arrangement that one layer is set to another with 45 degree of angle.

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Final Result

The plastic layer is covered on mold so it safe from Resin and can be use again

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Plastic layer

A fabric weighted for finding the quantity of ratio of Resin and Hardner

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Mixing Of Material

The ratio of Resin and Hardner is mixed in 2:1 and the total quantity is 3xweight of a material which is 150gm approx

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Mixing Of Material

Paste the resin dipped fabric on Mold then again make a layer of plastic on it and squeeze it over surface so it can attain a shape

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Cover with plastic

Place a breather and put the whole experiment into air bag which is ued to suck the air and build pressure on composite to attain the shape

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Cover with plastic

We wait a day to dry the material and the result was hard like rock

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After 24 Hours

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Final Result

Group Assignment

As a group assignment this week we did mill a very simple test design, a curvy shape in solidworks. Saved it as an .stl to machine it and then we generated tool paths in vcarve as following.. Initially, a new Vcarve file was opened and the dimensions were set according to the size of the model (222 x 101mm). Then by importing the Component/3D model(.sldprt file). Now cutomize your job as following.

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The 3D model is being set in the proper plane

In the next step we place the model at center so that the model comes inside the dimesnions we set.

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The 3D model is placed at the center

From the toolpath tab, we generate the toolpath for roughing and finsihing.

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The roughing is being done with the tool foam roughing 0.5 inch tool which is already added in the tool list

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>The preview of model after roughing

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>The The preview of model while finishing

The next step was to cut the model on the 40mm foam, the toolpaths were generated and then used in cutting on shopbot.

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>shopbot at work of roughing & finishing the model

We are using Jute as the fiber, we already cut the two pices on Laser cutter. The arrangement of the composite is shown below:

  • Layer1: Food wrapping plastic
  • Layer2: mold of oam covered with wrapping plastic
  • Layer3: 2 pieces of jute fiber mixed in resin
  • Layer4: wrapping plastic
  • Layer5: Breather for vaccum
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    >The arrangement of vacum for the model

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    >The model is being put in the vaccum for curing for at least one dayl

    The model was put for curing for the whole day and then the next day, we removed the mold and removed all the extra layers.

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    The mold is removed and the hardened composite is ready

    You may Download thsi Week file from Here

    Creative Commons License
    This work is licensed under a Creative Commons Attribution 4.0 International License.