To make (almost) anything

About Me Assignments Final Project Fab lab 2019
Molding and Casting
Individual Assignment

design a mold around the stock and tooling that you'll be using, mill it (rough cut + (at least) three-axis finish cut), and use it to cast parts

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
  • Mold Max 60 Safety DataSheet Review:
  • 5 Terre

    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:

    Product/Chemical Name: Mold Max® 60 Part B:

  • Hazards Identification
  • 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:

    Smooth-Cast 300 Series Safety DataSheet Review:

    5 Terre

    Smooth-Cast 305 Part A

    Product/Chemical Name: Smooth-Cast 305 Part A:

    Hazards Identification
  • 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.
  • Toxicological Information:

    Product/Chemical Name: Smooth-Cast 305 Part B:

  • 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:

    Individual Assignment

    1.Designing the Mold

    This week, I proceeded with the molding and casting process to make the soft gripper. So i decided to work this time with rhino .Rhinoceros 3D, also known as "Rhino 3D", is computer-aided design software. Rhino CAD is used primarily in architectural trades, industrial design and jewellery design.Source. You can download Rhino from HereAfter downloading if you have rhino account you simply login if not then you hve to first create account and login for usage.

    5 Terre

    Interface of rhino

    Here is the gif file of my design that i created in rhino

    5 Terre

    Design

    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 that i used for miling my design

    Following are the steps that i followed in the form of video

    3. Milling the mold

    For miling i used Roland SRM-20

    5 Terre

    Miling

    Here is the video of miling

    After completion of miling my design looks like this

    5 Terre

    After Miling

    4.Mold Time

    Before starting cast we must take some measurements . we add water to the mold so we can get idea for how much material we needed for my case its 30 gram , after that we add value of 1.5 of material factor material is more desnse than water

    5 Terre

    Calculation

    Here is the complete process that i followed for mold

    5 Terre

    Material

    The above figure is material that i used for molding both part A and Part B in group assignment i menioned about these material and their specification

    5 Terre

    Glass weight measurment

    before puting material into the glass we must calculate the weight of the glass and set weight machine into zero for
    measuring weight we used digital weight machine, and above figure show the weight of the glass

    5 Terre

    measurment after adding specific gravity of the material

    5 Terre

    Adding PartB of the material

    5 Terre

    Adding PartA of the material

    5 Terre

    Mixing the material

    5 Terre

    Filing

    After molding design looks like this

    5 Terre

    After Molding

    5 Terre

    After Molding

    5.Casting Time

    After molding the next step is casting for that i follow the same process that i followed for molding except material, for csting i used SORTA- Clear 37 that is silicone mold rubber , given below image of that material

    5 Terre

    SORTA-clear 37

    5 Terre

    Both Parts

    After casting the design looks like this

    5 Terre

    After Casting

    5 Terre

    Another View

    In casting there is some unbalance of ratios of both maerial so it not looks perfect yet and not dry properly, So my instructor suggest me to recast it . So very soon my casting version 2 will be released soon:)

    It's All About this week
    You may Download weeks 10 files from here

    This is all for this week

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