#Week16

Introduction


Actually I’m doing wildcard week assignment second time because I have done the design part while pandemic shutdown but after coming back to the lab I decided to change it.
But I will keep screenshots from that project on my page.
After coming back to the lab I started doing my wild card week assignment to design and produce something with a digital fabrication process.
I like paper recycling Ideas and start working in that direction. First I design the mold, then print it after start recycling procedures. Actually I have done some bioplastic
stuff as well.

Design

First of all, I need to design a mold in which I’m going to put the material in our case that is recycled paper or bioplastic. I’m going to make an organizer for the lab. As usual, we are starting the design from a sketch which is a very basic drawing with 5 rectangles. then I extruded it with a taper angle to make the removing process easier. after these two basic steps, there is a time for the third one to add the fillets. Filets are making the final product look better and making the molding process easier as well.

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Mold making

because my mold is not so big it can be 3d printed as well. The infill of the mold is 0, the thickness of the wall was 5 layers. that are pretty strong settings for such a basic model. It took around 9 hours to print.

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Bioplastic from gelatine

As I was interested in bioplastic as well I ask Azniv Hovhannisyan to make to help me with preparing the bioplastic. Actually I was helping her in that process because she had more experience with the bioplastic. so we take

  • 240ml water
  • 63g gelatine
  • 19g glycerin
  • Food coloring (optional)
  • and heated till 95C while constantly mixing. Then we should leave the solution a bit until bubbles are gone and fill into the mold. But we didn’t wait because we don’t have a patient and were scared that it will cool down.

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    First, we fill up my mold then Aznive’s mold, then we realize that it was too much gelatine, and start filling up all the molds that we found in the lab. I remove the organizer from the mold after one hour it was still raw but it was okay.

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    Paper recycling

    After we start the process of paper recycling. for that procedure we need

  • blander
  • any kind of paper
  • rice
  • water
  • 1.The first step is breaking down the paper into smaller pieces.

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    2.The second step is to cook the rice

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    3.Thread put the paper and rice into the blender add some water just enough for stirring the mixture

    4.Fourth blending the mixture until getting a smooth mixture.

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    5.The fifth step was the worst one we need to squeeze the mixture. and that was lats say unusual.

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    after squeezing we can put the substance in the mold. actually when I start filling the mold understand the mistakes and the trikes that can be used for paper recycling molds but I worked with the mold which I made and with the hope that it will work.

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    After all the procedures described above, I put a piece of MDF on the mold, put some clamps on it and live it 15 hours.

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    when I open the mold I discovered that there it is steel wet and decided to put it in the oven. I set the temperature 60 degrees C and keep it one. one hour is not fixed but I didn’t have more patients. After taking out the mold here is what I found.

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    Conclusion

    In conclusion, I want to say that next time I need a different type of mold for paper recycling with removable walls and inserts it has to be like a constructor.

    Files

    Engine.stl Engine.f3d hingr.f3d

    Experience while shutdown

    So making the mold is my major task. Because of the pandemic, we don’t have axes to the lab that’s why I have done only CAD and CAM part. Here are all steps. first I designed the rear fender. Because of my work and my profession I am pretty familiar with this kind of process and know a little bit about even if I haven’t known, that is a very simple process that can be done after few tutorials. So let’s go on after having the fender ready we need to design the mold. Our mold will have two parts top part and bottom part. the molds have to have the tapered faces and they need to be in one direction to let the part go out from mold in our case it will be a fender. All design process took only 4 steps by cutting and combining (join) the parts. also not forgetting to offset the top part tho have a place for the paper. In this design, the gap is 3mm and as a result, the thickness of our part will be 3mm as well. Also, I added some holes for letting water go out from the mold (recycling paper is a wet process). the mold will be made from MDF on the shopbot. Also, I have done the CAM part in the fusion’s manufacturing workspace using pocket and parallel toolpath. For the pocket, I gave 1mm max stepdown and 50% tool’s diameter stepover and for parallel, I gave 0.5mm stepover. Endmill for the pocket is 16mm diameter and for parallel is 10mm diameter

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