Assignment Week9
Molding and Casting
![](style/images/assignment09.png)
This week’s assignment is "design a 3D mold, machine it, and cast parts from it”.
I tried to use 3D scan data of week5’s assignment, and make chocolate casting.
Making mold data
In week5’s assignment, I scanned Japanese famous chocolate snack “Black Thunder “ ,using MDX-20 scan probe.
I had exported STL format 3D data from the scanned data.
I imported it to Rhinoceros file, and edited to mold data.
When I had imported STL format data, It had been opened as mesh data of "Black Thunder".
So I changed mesh data to polysurface data.
![](style/images/assignment09mold01.png)
In this case, mesh file's resolution was very high, so process of Rhinoceros's process was very slow.
Therefore, 3D data of Rhinoceros is very large size (over 230MB!!).
So I uploaded to Thingiverse. It can download here.
Making mold of mold
Next, I made mold using MDX-20
In this time, I used Roland DG's original software "MODELA Player"
And, I selected modeling wax for making mold.
Tools
I prepared for milling.> Tool : 3mm Ball End Mill
> Material : Modeling Wax
> Feeds & speeds --It's default setting of "MODELA Player"
>>Rough cutting > XY : 15mm/sec, Z : 1mm/sec
>>Finish cutting > XY : 15mm/sec, Z : 5mm/sec
Setting zero point of endmill.
Next, I started setting of "MODELA Player".
![](style/images/assignment09mold02.png)
First, I setting of "Rough cutting". I describe setting flow.
![](style/images/assignment09mold03.png)
1. Check the size information of 3D data. In this case, 90mm x 60mm x 35mm.
![](style/images/assignment09mold04.png)
2. Select the working surface. In this case, I selected upper surface of model.
![](style/images/assignment09mold05.png)
3. Imput the unit scale number.In this case, I imput 0.1. Because Rhino-data unit is cm, but MODELA Player unit is mm.
![](style/images/assignment09mold06.png)
4. Imput diameter and shape of endmill. In this case, I imput 3.0mmm, and round shape tip.
5. Select the kind of material. In this case, I used modeling wax. So, I select it.
6. Select the kind of milling style "Rough cutting", or "Finish cutting". In this case, I selected "Rough cutting".
![](style/images/assignment09mold07.png)
7. Set layout of milling area of material. This window can call "Option > Layout setting".
![](style/images/assignment09mold08.png)
8. Execute!
9. Change to Finish cutting mode and repeat execute!!
![](style/images/assignment09mold09.png)
10. Complete!!!
Dust of milling can recycle. I collected it.
![](style/images/assignment09mold10.png)
Making mold
I made mold using "mold of mold".
![](style/images/assignment09cast01.png)
I prepare mold of mold, silicone as mold, paper cup, stick for mix, and mass scale.
![](style/images/assignment09cast02.png)
1. prepare 2 silicone liquid in paper cup, A and B, using mass scale.
In this case, mix ratio is 1:1.
I used "PROSILICONE PLATINUM HTV-4000" sold by ENGRAVING JAPAN.
2. Mix 2 liquid to solidify.
Stronger, faster, and not leave.
![](style/images/assignment09cast03.png)
3. Cast in the mold of mold.
In this time, paper cup should be higher position.
Because, If we cast from lower position,invade bubble.
![](style/images/assignment09cast04.png)
4. Pick up the mold.
![](style/images/assignment09cast05.png)
5. Cast chocolate to silicone mold.
![](style/images/assignment09cast06.png)
Complete!!