Week10


For this week we needed to review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them as a group assignment and 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 as a invidual assignment.

Software


WinPC-Nc

Tinkercad

Fusion 360

molding

We used soap to make our positive for the molding because soap is cheap to buy and also easy to cut.



Group assignment(Read more aboutthe group assignment.)

molding



Invidual 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 as a invidual assignment.

Tinkercad design


molding

I made my design in Tinkercad and i made a foot with two shapes of toes.The middle toe has the kerf that the design suppose to have.Save my design in .STL format and then imported my file in Fusion 360 to add the parameters for cutting my design.


This Design has:


1.Cylinder


2.Half Sphere


3.Ball Handle


4.Extrusion


5.Box

molding

Select the half sphere,the cylinder and the ball handle to get the toes for the foot.

molding

Select the extrusion and form the other part of the foot.After doing that group all shapes to make them one body.

molding

Select a box and make it to place the foot in it to get the form.

molding

After placing the foot in the box and click on hole.

molding

After doing that select the two shapes and then group them.

molding

Select another box and make it bigger then the previous one.

molding

Rotate your design 180 degree and place it on the box.

molding

After putting it on the box ,click on hole and then you will get theform in the box.

molding

Here you have the design of the mold


molding

After importing my file into fusion,you have to check if your design has the same size like the size you gave it in Tinkercad.If you are working with a soap with a special size,you have to make your design that fit in that special size soap.



molding

The soap size i used is 80mm width and 50mm height and the depth is 35mm.So i scaled my design to fit in the size of the soap.

board

If the mill you're going to use is not in the library,you have to add the library.For the pocket cutting i used the 1/8" flat endmill and for the parallel cutting i used the 1/16" ball endmill.For using the milling machine i added parameters for cutting the soap.I have selected for pocket and also parallel.Pocket means that it wil cut on the inside of the soap and Parallel means that it will cut parallel lines on the soap.



Pocket Parameters :


Parameter Value
spindle speed 16000 rpm
cutting feedrate 1000mm/min
Feed per tooth 0.03 mm
Plunge feedrate 762 mm/min


Parallel Parameters :

Parameter Value
spindle speed 16000 rpm
cutting feedrate 1000mm/min
Feed per tooth 0.03 mm
Plunge feedrate 762 mm/min

board

To make the parameters in fusion work on the stepcraft milling machine,we downloaded the winpc.nc.cps file so that we can save the design in .nc format and use it on the stepcraft milling machine.


board

Before you begin to mill make sure your object fasten to the board.


board

Pocket milling using soap and this is the outcome

board

Parallel milling using soap and this is the outcome


board

For the rubber you have to mix liqued a and liquid b together and you have to stir it wel.If it isn't stir wel you will get holes in the rubber.After stiring it you have to let it dry.I left mine 12 hours to dry.We didn't have the rubber liquid in the first time so we tried silicone to look if it works and it didn't came good.

board

Putting the mix into the design.


board

The mold should be like this.



board

For the cast you have to mix liquid a and liquid b together and you have to stir it wel.If it isn't stir wel you will get holes in the rubber.After stiring it you have to let it dry.I left it for 24 hours.

board board

After letting it dry the cast should look like this.



Files

Footmold Fusion
Finish cut
Rough cut
Footmold tinkercad