11.Molding and Casting:

14-04-2021 | Jai Hanani

1. Objectives:

2.Group Assignment: review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them

3.Individual Assignment:

4. Files, Planning, Tools:




  1. I was away from Lab this week, too, due to covid uncertanities
  2. First, I went through Micky's Documentation: Micky's,and FabAcademy Tutorial: Tutorial
  3. First, I presumed that milled-wax is the mold, but later I realized that from the milled-wax you will cast the mold, and from the mold you will cast the objects.
  4. For this assingment, I want to make a 2D Model(Image) Molds, and I will choose this image:

    Rust Programming Language Logo.

  5. My Fusion360 license was expired, I upgraded to educational license. Then, I imported the model.
  6. I am following this particular instructable and this video to help me along while I do CAM in fusion360: Instructable, Video
  7. I was swiftly turned by instructor - it is not a valid assignent, becuase there are no curves, and z-axis is not variable.
  8. I have created a sphere, cut it in half, and exported it to 'manufacture' section of the fusion 360. There I chose, New setup.
  9. Next, I configured the stock to appropriate size for the model:
  10. Next, I chose the 'Home' point as the corner point on the top surface of the stock, using the 'Stock box point' feature.
  11. Tool Library:
  12. Selecting machining boundary, tool containment, model to be cut:
  13. Setting the heights. It is default for now.
  14. Tool path is generated. Size of the original model was extremely small.
  15. After correcting the measurements, I have tried it again. It worked. Picture of simulation in-process:
  16. This was a 2d face operation, used to cut between the top layer of the stock, and the top layer of the model. Next, I will try 'Adaptive Clearing', a 3D operation.
  17. It worked, but the holder is hitting the stock.
  18. New Design:

  19. I was yet to come up with a design. I was browsing through my old photos, then I came across this photo. I knew what I was going to make.
  20. The Great Platform of Hampi
  21. The CAD Model:
  22. After Reaching The Lab:

  23. I decided to make a fidget spinner.
    Credit: Wiki

  24. Extrude it.

  25. Extrude the area between the inner-circle and the middle-circle.

  26. Cut the center cirlce.

  27. Fillet it everywhere.
  28. The Mold and The Cast.
  29. The thing to be milled on the wax.
  30. I extruded a offsetted-circle up, to hold the bearing there.


  1. I used this Fab-Tool-Library, as the tool in the CAM Process.
  2. I used a 3mm-diamter flat-end mill as the tool-bit to mill my wax.
  3. The cutting data, like spindle speed, cutting feedrate, plunge feedrate, is set here.
  4. Adaptive Clearing:

  5. 2D Pocketing and Scalloping:

  6. Like I mentioned above, we can mix PART A and PART B in 1:1 ratio. Mix it well, and pour it in the wax. Let it stay for 4+ hours.
  7. OUTPUT:

  8. Casting:

    For Casting, I used Smooth-On SMOOTH CAST 305.They are 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. These resins readily accept fillers (such as URE-FIL™ 3 from Smooth-On) and can be colored with SO-Strong™ or Ignite™ color tints (Smooth-Cast™ 325 series accepts pigments better than the Smooth Cast™ 300 series). Fully cured castings are tough, durable, machinable and paintable. They resist moisture and mild solvents. Applications for Smooth-Cast™ 300 Series Liquid Plastics include reproducing small to medium size sculptures, making prototype models, special effect props and decorative jewelry.
  9. Both these parts must be mixed in 1A:1B proportions.
  10. Mixing:

  11. Pigmentation:

  12. Pouring:

  13. Final Product:

  14. The final cast was not 100% success. The SMOOTH-ONs we had available in our lab were all expired. Though we tried to procure more from the market, we could not, given the state of covid-lockdown we were in.

  15. Bad Initial Cast:

    Problems Were:
  16. Group Assignment:

  17. This weeks Group Assignment is to review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them.


    The Smooth-Cast™ 300 Series 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.


    Aditya Easy Cast Transparent Epoxy Resin

    Aditya Easy Cast Transparent Epoxy Resin - 33-750gm is very easy to use. Aditya Clear Cast Epoxy 33 can be casted into moulds of Silicone Rubber to Create Transparent Crafts, Lockets, Jewellery and Trophies. Pigments are available to make Opaque Colour Castings. It comes in Part A and Part B. Features include:

    Rules to follow during molding and casting

    We had two main materials for the mold in our lab for the silcone mold. One was oomoo and another was aditya. Aditya was from the local vendor which only mentioned the ratio of the mixture but not the pot pot time and the setting time. so we decided to use both to know about them and then use it to make a mold. Sorta-Clear 37

    SORTA-Clear 37 is a premium water white translucent silicone rubbers (platinum catalyst) which cure at room temperature with negligible shrinkage. These rubbers feature high tensile and tear strength. They offer the convenience of a 1A:1B by volume mix ratio. They are ideal for making prototype, jewelry or other molds of any configuration where model visibility is important (i.e. extracting a model from the mold via cutting). Materials such as urethane, epoxy or polyester resins can then be cast into these silicone without application of a release agent. Other materials such as wax and low melt metal alloys can also be cast into the mold made out from this rubber. These can be pigmented with SILC Pig™ silicone pigments. They are also FOOD SAFE and can be used for culinary applications including casting chocolate and other confections.


    Since the SortA-Clear 37 which we had been using was old, there were bubbles already in the rubber before mixing. First we decided to save time for understanding the process safety and the quality of the mold so used the old milled was for molding. Main thing first, since the mix has a pot life of 25 min, keep everything ready on the table so that the process goes uninterrupted, wear your safety gears like gloves, masks, and glasses. First trying the SortA-Clear 37, it had the ratio of 1:1 by volume and 100:139 for part A : Part B. There are 3 ways three ways to mix Part A and Part B.

    In our case, we used the second one, mix by weight, but took reference of amount of material by volume. To estimate the amount we should be mixing, the volume of the mix has to be known so as to prepare it so take a cup, translucent or transparent, pour water into the milled part , pour the water into the cup, mark the total volume and mark half the volume. Now put the cup on the weighing scale set the weight to zero with the cup (In case you cant set zero the weight with cut, please consider the weight of the cup and use the difference for calculation). Pour Part A up till half mark we made on the cup or a little bit more for being safe of amount of mix. Weigh it and add Part B by weight ratio of 100:130 (A:B), i.e if the weight of Part A is "x" gm "1.3*x gm" of Part B should be poured. Then mix it with only horizontal strokes, not vertical strokes or it might add the air bubbles into the mix. Less the air bubble, better your mold will be.slow mix has to be done so that the air bubble do not form. You might use vacuum chamber to remove the air bubbles if you have it in your lab. We did not have it in our lab so we were unable to use it. If the bubble comes in the surface where the material is cased, you might have defect in your mold and the part which will be cast out of that mold. Remember that the pot life of the mix is just 25 minute of do not let the mix stay for more than that. It might be different for your material which should be mentioned in the datasheet.

    After the mixing was done, pour it slowly from one end of the mold letting it flow smoothly. The trick according to our instructor was to pour it slowly stretching the flow so that if there is any bubble in the mix, it will go out during the stretch. After the mix was poured onto the wax, we shook it so that the mix gets into all corners and if in case if there is any bubble trapped, it might come up to the surface. The mix has the cure time of 4 hrs, so at least leave it for 4 hrs untouched. For us we left it overnight as we did it in the evening. After it is cured, the mold can be ejected easily as it is rubber and can stretch. Same was done from the aditya silicon with the ratio of 30-14gm hardner per 1Kg rubber. It was poured into another mold but did not cure even it was left for one and half day. so we rejected that.