Moulding and Casting

:blush: Updated for 2020 evaluation standards!

  • Group assignment

    • Review the safety data sheets for each of your molding and casting materials
    • Make and compare test casts with each of them

  • Individual assignment

    • Design a 3D mould 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.

Learning outcomes

  • Design appropriate objects within the limitations of 3 axis machining
  • Demonstrate workflows used in mould design, construction and casting

Have you?

  • Linked to the group assignment page
  • Reviewed the safety data sheets for each of your molding and casting materials, then made and compared test casts with each of them
  • Documented how you designed your 3D mould and created your rough and finish toolpaths for machining, including machine settings
  • Shown how you made your mould and cast the parts
  • Described problems and how you fixed them
  • Included your design files and ‘hero shot’ of the mould and the final object

FAQ

Should I mill a mould for the group assignment?

Answer: No, group assignment is for you to get familiar with the materials and the processes.

Should I read the MSDS and TDS this week?

Answer: Yes, always. Document the main points.

I want to only make a wax mould, and cast something in it. Is that acceptable?

Answer: Only after you learn and go through the 3 step process. To break the rules, you have to master the rules.

What does 3-axis milling mean?

Answer: You should have smooth tilted or curved surfaces instead of "steps" towards axis Z.

Can I 3D print the mold? Can I do a lasercut?

Answer: No, for this assignment you must mill the mould using a CNC milling machine. After fulfilling the requirements, please go ahead and experiment other techniques for fabricating moulds.