Fab Academy 2015, Dong-Hyun Kim
Composites
Molding Design
To making a mold, first draw full dimension of box little bigger than original dimension of the object. Put original model and remove overlapped part. It is done.
Important thing is CNC machines end mill size is already set so, it can cause intrude.
That’s the reason why we have to do trim or chamfer when we design to remove intrude.
Make a 3D mold
Cut thick iso-pink board with CNC. The thing is you never change the view point before make g-code because Fab Module directly make g-code as it looks. If you change the view before done G-coding in Fab Module you can’t get output what you want.
You can’t move the view before it show in gradient.
- Diameter : 6.0mm
- Pass Depth : 3.0mm
- Spindle Speed : 14000rpm
- Feed Rate : 200.0
- Plunge Rate : 60.0
- Material : iso pink 50T
Composites
Set materials for compose; Poly coat, Hardener, Mold, Sheets of woods for composing and Fiber glass.
You should do simulation before you start composing to check any possible defects and sequence of composing.
You may have smaller result in case of curvy mold.
To do the final project middle of layer I put LED inside of it. You can get dim light ooze from sheet of acrylic.
Before start composing put vinyl on the mold to prevent destruction of the weak iso-pink mold. While epoxy hardened mold easily break.
Poly coat was harden so fast. Because of that I have to move fast. It is efficient to do it separately when you have to do a lot of quantity
Check finally if there’s no problem while it bended and cover it up with upper mold. Press the mold with heavy stuffs (best way to do this is clamp upper and down mold to gather) while it harden most ideal way is using plastic bag full of water to give even pressure.
Extra work
I turn on the LED while it composed. LED light ooze out indirectly.
Compose with the pipe.
TIPS
- Use plastic bag while composing to reuse the mold.
- Use good quality of fiber glass; weaved one, because it will gives you fine output.