Mohammad Al Hamadi

Molding and casting

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.


I drew and designed this shape using the Fusion 360 tools, using the (Create Sketch) and (Create Model) tools,
This is the first step I should take, as shown in the pictures below:

After creating and designing the shape, I'll cut it in half by drawing a rectangle with a width of 0.1 mm and along the design in the middle and using the Extrude Tool.

I made a rectangle to size the template that I will be working on After moving the parts as shown below:

From Create, we choose the Extrude command and then drag the 40 mm high shape that appears in the image below.


The design is ready to be milled and then I will save it and export it to an STL file.

This is the file:STL
After completing the previous steps and preparing the file, I need to have the Roland SRM-20 prep to grind it properly.
The CAM software I used with the Roland SRM-20 is the SRP Player.
SRP Player CAM software simplifies everything from reading 3D CAD data to setting milling requirements. It enables users to generate optimized tool path data by simply inputting information according to step-by-step instructions displayed on the screen.

I will set the origin of the side of the body so that the machine can grind it correctly. Second: I will choose the type of grinding and each type depends on the design details and also each type has a special brush.
And I chose - the fastest cutting time using the 1/8 SE 4FL bit BallNose.

Third: Choose the type of material which I will milling it, Fourth: The program will simulate the milling process and display the expected completion time.

After adjusting all the settings, I click on start cutting


Before starting milling I will prepare the machine to be ready for milling.
First, I will dismantle this piece of the machine and raise it to the top in the place designated for it, because the machine was equipped for drilling the board.
Using a ruler, I'll outline the crayon to mark the center for zeroing x y z.
Second, we stick the wax mold through the double-sided adhesive to the base of the machine

Third, I will install 1/8 SE 4FL BallNose bit in the specified location and make sure it is installed correctly

I'll be zeroing x y using the control panel in the middle, and also z-zeroing using the paper and in order to properly beeping so as not to break the wax mold.

Next, using the SRP Player, I'll start by cutting the wax template

After waiting for several hours, this is the result below:



After preparing and milling the mold, we will proceed to the next step, which is casting.
Mold Max 60 Silicone Mold Making Rubber
Mold Max silicone rubber is good for revealing the smallest details and is suitable for a wide variety of related technical and industrial applications including making molds for the reproduction of prototypes, furniture, sculpture and architectural elements. Mold Max silicone can also be used to cast a variety of materials including wax, gypsum, and metals.
The Mix ratio is 100A:3B by weight.

To find out the volume of materials that will be consumed by filling the dug mold with water and pouring water into a cup, and then I know the weight of the water by weighing it on the scale after placing an empty cup of water on the scale and zeroing the scale and then putting the cup filled and it was 266 grams.
266 grams of material A, this means and according to what is mentioned in the data sheet must use 3 grams of material B, which is the material that hardens silicon. 7,98 grams. I must use 266 grams of material A & B.




After the completion of the casting and the passage of a period of time to ensure that the mold is ready and after dismantling the mold from the wax mold, the result is as follows.


The Smooth-Cast™ 305 of liquid plastics are ultra-low viscosity casting resins that yield castings that are bright white and virtually bubble free. Vacuum degassing is not necessary. They offer the convenience of a 1A:1B by volume or 100A:90B by weight mix ratio. The differences between them are pot life and demold time.

To find out the weight of the material I will be using, by filling the Silicone Mold Rubber with water and pouring it into a cup. And then I bring the scale and know the weight of the water after zeroing an empty cup on the scale and the weight of the material was 56.6 for the smooth material cast 305 white liquid plastic, and I will put a rubber around the Silicone Mold Rubber to not allow the smooth material molded 305 white liquid plastic from leakage out of the mold .

After mixing the materials well, I will pour the material into the mold, and I made two syringes to facilitate the pouring process, as shown in the video below:

After the casting is finished, I will leave the mold for a short period of time to be ready

Then I will disassemble the Silicone Mold Rubber to see the result

After removing the excess from the shape, it will look as it appears in the image below



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