Assignment

Group assignment

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

Group Project here

Individual Assignment

1. 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.

Table of Contents

1. Design

1-1 Searching

1-2 Fusion360

2. MANUFACTURE

3. Tiny Robo

4. Moulding and Casting

4-1 Mold Star™ 20T

4-2 Smooth-Cast® 326

4-3 Step

1. Design

1-1 Searching

• I found this while searching through Pinterest to make something useful small.

• This is Thumb-Ring Page Holder!

• I once had a hard time reading a book with one hand. The book was not fully opened, and it took a lot of effort to be fully opened.

1-2 Fusion360

↓Desgin by Fusion360

• I wanted to add a symbol related to me, so I added the Aquarius of Zodiacal Signs and the rat of Twelve Zodiac Signs icon.

• After the design, I wanted to check the size and shape, so I printed it with a 3D printer first.

↓An Object Printed From 3D Printer

• That's a good one! proceed as it is

• Back in fusion, In addition, the cylinder female male assembly was made to secure the mold and the square assembly was made to prevent it from going wrong.

• Also, to make it easier to pull out the mold, I used drift funtion to cut the side wall by about 2 degrees.

2. MANUFACTURE

• Next, I used the MANUFACTURE function in Fusion to check if there was a problem when I cut to Tiny Robo, predict the time, and make a file.

• First, I set the x,y,z axis in the setup and chose the model.

• I decided to use 3mm and 0.1mm emd mill, and added tools to the tool library.

• Select Adaptive Clearing in Milling to set the Cutting Feedrate → 1000mm/min, Spindle Speed → 10000 RPM, and Stock to Leave → 0.5 and Lead & Transitions → 0.3 each.

• For the second task, we added the scallop option and revised the Stock to Leave figure to 0.

• The 3mm endmill work setting was carried out without any problems, but the 0.1mm endmill work setting was not carried out due to this error.

• In the end, the details (star sign and twelve zodiac signs) that were about to be cut down to 0.1mm had to be deleted.

• Solutionhere

• The setting value exists here. Follow this solution to fix the problem.

• The simulator was used to check if there was a problem in the wax-cutting phase.

• There was no problem and the I set the processor to mach3mill in the post process and saved as a .tap file.

• The blue part I chose is unnecessary work, so I deleted it.

• Because I had to use Tiny Robo and proceed with molding and casting, I couldn't save the details by design. There were many other restrictions.
• The size of the wax is limited, so the size of the mold is limited.
• Small details are limited (less than 5mm).
• Because the viscosity of the material that makes molds is not the same as water, you cannot make very detailed parts.

3. Tiny Robo

• Put a block of wax on the sacrifice board, fix it with a glue gun.

• The sacrifice board has been secured.

• Call the .tap file and set it up.

• The time required is 12 minutes, the speed is 720, and the rpm is 10000.

• I set up the z,x,y axis in Tiny Robo,and based on my files. And start cutting

• And connect the supplies by referring to the picture below.

• My wax board that has been cut.

4. Moulding and Casting

4-1 Mold Star™ 20T

• I wanted to get the mold out of the hard wax easily. So I found a soft material while maintaining some form. What I found was Mold Star™ 20T.

• About Mold Star™ 20T here
• Mold Star™ 20T is an easy to use Shore 20A translucent platinum silicone that is mixed 1A:1B by volume (no weighing scale necessary).
• It features a relatively low viscosity and vacuum degassing is not required for most applications.
• Pot life is 6 minutes and cure time is 30 minutes at room temperature.

4-2 Smooth-Cast® 326

• This material is from the last casting.

• About Smooth-Cast® 326 here
• The convenience of a 1A: 1B mix ratio by volume and has a very low viscosity.
• Demold times range from about 10 minutes to 2-4 hours (depending on product, mass and mold configuration)..
• Note: Large mass castings will get very hot and shrink more, depending on mold configuration.

4-3 Step

• Before I used the material, I had to calculate the volume of mold I wanted to get.

• How to Check Material Volume(g)(Youtube Link for Reference here)
1. Make a "construction" that will be a cover.
2. Fill in the empty space using "Boundary fill"(CREATE - Boundary fill)
3. Change the "physical material" into water.(Click Right Button - "Physical Material")
4. Check the weight of the mess by entering the "Properties".(Click Right Button - "Properties" - Check "Mess")



5. 72g!

• 72g of material is needed. Since the ratio is 1A:1B, check the scale of 36g each and put it in the beaker.

• Mix them together.

• Put them all in mold.

• I used a softer silicon mold star 20T to easily pull out the mold from wax.

• Last step!

• As soon as he was about to calculate and work on the casting material, Hyun-ho created too many materials without calculation. So I decided to use the leftover materials. (He saved my time.)

• The material was poured into the mold and clamped to prevent the material from leaking out.

• A very pretty model came out.

• Remove additional parts from the top with the sanding machine.

• Unfortunately, a blister formed.

• Retry!

• It's very well made, except for the tiny hole.