In the first case, I think about doing something big but my instructor tells me that Luis you have to do something small, I was sad but in that, I have an idea, I think and the idea of ​​making a Kunai, a Japanese weapon, occurs to me, as I like Japanese culture and anime Naruto I thought why not make me a kunai with some symbols engraved on it.

TRIAL 1. I designed in the sofware Rhinoceros my kunai.
Picture 86.

Picture 86.


I share my file of my Kunai:
Kunai Stl
Rhinoceros File

STEP 1. I designed my matrix for the mold finished of my kunai.

Picture 86.

Picture 86.

Picture 86.

Picture 86.

Picture 86.

Picture 86.


I share my file of my Mold for my Kunai: Rhinoceros Mold File

TRIAL 2. When I finish my Kunai mold my instructor and me knows my Kunai design doesn’t fit the requirements because it is difficult quiet impossible to print because is to small. So I decide to do a different design, I thing and have an Idea why not do a Shuriken. So I start all of the begin. below are my steps of my process

Picture 86.

Picture 86.1.

I share my file of my Shuriken:
Shuriken Stl
3Ds Max File

STEP 1.I designed my matrix for the mold finished of my Shuriken.

Picture 86.1. I import my shuriken design to rhino because here i design my matrix for my Shuriken Mold.

Picture 86.1.

Picture 86.1.

Picture 86.1.


I share my file of my Mold for my Shuriken: Rhinoceros Mold File



STEP 2. The Wax that is going to be used to create the matrix for the mold.
Measurements: 148mm height x 88mm width x 37mm height


MACHINABLE WAX CHARACTERISTICS:

-Appearance: Solid blue
-Melting point: 240°F
-Softening point: 157°F
-Flash point: from 465°F to 575°F
-Hardness: 53 (Shore “D” Scale)
-Dimensions: 148mm x 88mm x 37mm height


FEATURES:

-Non-abrasive
-User-friendly
-Self-releasing/self-sealing
-Able to be glued
-Self-lubricating
-Wide variety of sizes



STEP 3.SETTING PARAMETERS in Aspire 9

Picture 86.1.For the configuration of the parameters to mill the wax we use Aspire9 software.

Picture 86.1.Adding the dimensions of the wax

Picture 86.1.
Then we open the STL file of the Bullet design.


Picture 86.1.
We choose the First mill for roughing and the corresponding parameters after finding the parameters using the web.


Fablab Speed and Feeds Calculator

After having the milling parameters for wax, i used it in the Aspire software.






STEP 4.Milling the positive mold done in the WAX done in Wax with the Roland Milling Machine SRM 20

Picture 86.1.
Then the process of milling using the 1/8 flat mill for rouhging and the second step using the 1/8 round mill for finishing the molding.




Video.1. Mill 1/8 rouhging.


I share my file of my Mill 1/8 rouhging. Roughging-Mold File

Video.1. Mill 1/8 finishing.

I share my file of my Mill 1/8 finishing. Finishing-Mold File








STEP 5. Here the Matrix finished to obtain the mold, YEAH!. My mold are ready to the Silicone RTV step.


STEP 6.Making my Mold-Silicone from the WAX-mold
I used 100g or Silicon F-20 and pour 2g of the catalizer.



I worked on the extractor hood in the chemistry lab at the school where my partner works.
Because of the VOC 19 my colleague very kindly proposed to go to work in his laboratory at the Villa Caritas school since there he has a mini FabLab called MakerSpace.





I stir the mixture.



I pour it into the wax






Finally, I have to wait about 6 hours until it dries completely. But I have a problem, my silicone does not dry. do not believe me but I confused something very silly, I do not know why I thought that 2g = 2drops in Spanish 2gotas of catalyzer, I confused the g with drops instead of grams. the solution was that I had to make a new mixture and this time it did count 2 grams of catalyzer.

First I was clean my mold and again pour the new silicone and wait 6hours more.




After the 6 hours more, Here how the mold appears.










I prepare the silicones mixture according to the chart above. I did it the fume hood of the Chemistry Lab of the school due to safety concerns.

The CASTING:

-RTV SILICONE Mold

Chemicals	Quantity
.RtV Silicone	100 grams
.Catalyzer	2 grams

-Epoxy Resin Object

Chemicals	Quantity
.Epoxy Resin	20 Grams
.Colorant	20 Drops
.Catalyzer	20 Drops

STEP 6.Introduce the resin into the mold of silicone
I used a 20ml syringe to introduce the resin into the mould because the hole is very thin. At the beginning is seems to work but not at all due to some part without resin covering.






I wait for three hours to check my casting. First trial with the colorant gray, looks good but not enough because one side was holes because when i pull the resin into the silicone mold some bubbles of oxigen introduce too.




So I desied do and other resin mold, in this case I used without colorand.




After pour the resin into the mold, I had leftover some resin in my glass. So I think why not do a decorate objet. So I put a dissected fish into the leftover resin. But the fish fload over the resin so I push it gently until it is dipped into the resin.


So I desied do and other resin mold, this was my third mold. In this case I used blue colorand.




After pouring the resin into the mold, I had a bit of resin left in my container, but it had dried very quickly, so I broke the container to remove the resin block.




As I had leftover the resin that went wrong the first time, I decided to put it to good use, so I decided to reuse it, I added more catalyst and I poured it into another container and finally I placed my resin block. And this was the result.



Without the container






STEP 7.Final view of the all shiurikens I made.

========== learned/conclusions ==========

=============== FILES ===============