Group assignment:
- Review the safety data sheets for each of your molding and casting materials
- Make and compare test casts with each of them
Individual assignment:
- 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.
Group assignment:
for the group assignment you can find the link from here we tested these materials
Individual assignment:
Start by creating a new body , and choose the plane axis you will start your design on
Then I changed the workbench to spread sheet to add the parameter that I will use in my design
I divided the parameter into 4 gropes
- Joint ; this is the dimention of the joint it has the angle ,material thikness , and clip is how long the Rod will go inside the joint
- Rod : this will be wood rod that will be cut with cnc to create the structure when connecting it to a joint, it has the width and hight
- Mold ; this is dimention of the cilicon mold it will be depend on the dimention of the joint and then just to ad margin from the joint , it has the margin for x,y,z
- Stock : is the dimension of the Wax mold that I will mill to create my mold , it has the dimension of it along the axis xyz
Then I add alias to the value of the sells to make it accessible inside the design
Then switch back to part Design work bench , and create new sketch
In the sketch I Drew the base of the joint , I used the dimension from the sheet and connect it to the design
I changed the view to the right and created a sketch and draw the path and the angle and made them constrained to the spread sheet parameter
Then I used sweep function to make the sketch seep through the path
Then created a sketch for the mold at the right view
Then used the pad tool to extrude it
Then I made clone of the main body
Then using the Boolean function I took the deference from the mold and made a hall in it
Then created another sketch underneath it and used pad function to extrude it
Here I made the stock clear so I can see the mold inside it
Then I used the Boolean function to take the deference
Then export the file to STL format
Repeat the same steps for the second half and export the files as STL , Then you need to creat a tool path depending on the machine you have and the software , you can use MIT mods , fusion360 , modela 4 player.
Generate Toolpath and mill
Since I hve SRm-20 I will use its software modela 4 player to create the tool path
Now open the design in modela4 player
and the chose the material to be wax mold, and start a new process
- i will use roughing as
- then choose the bit size , i used 2.1
- and set the location for the mill to start
- then generate the tool path
Save the tool path and click cut to create the tool path and send it to macine for the magic to happen
Here is a timelapse video for me making the design
And then making the mill and mold
Result of the mold
this is the final result for the silicon mold
Time to make plastic Mold
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i used smooth-cast 305 as the matrial for my mold, this material has to be mixed together to produce white color plastic, and you have to follow this instruction
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Shake th bottle before using
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pour the same amount of the tow material the ratio is 1:1
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mix them good for 1 min
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then pour them into the mold and leave them for 30 minutes
Step 1
the first step is to pour the same amount into the two cups , the ratio should be 1:1, so i used the digital iused the digital scale for booth cups it was 38.1 grams
Step 2
pour the two cups into another empty cup, and fill it with tow material.
Step 3
now Mix it good for 1 min
Step 4
then pour the mixed cup into the mold and wait for it 30 Min
Final result for the mold
here is becuse the material i used it has some softness it stretched when i took it out of the mold , but the result was good to see the exact location for the holes and how they are connected to each other
problems and how i solved it
every thing was going right as i planned , but the problem was when i wanted to take the plastic material out of the silicon mold , the plastics reacted with the silicon and i couldn’t take it out as you see in the picture.
to solve this issue i used WD-40
