- Design and produce something with a digital fabrication process not covered in another assignment.
- Possibilities include (but are not limited to) composites, textiles,biotechnology, robotics, and cooking.
Introduction
This week we need to something that not covered in another assignment and also must incorporating computer-aided design and manufacturing.we have some options like we can use composites, textiles, biotechnology, robotics and cooking.After the professor class i was very much interested in composites so first i was going make something usefull using composites .
Composites
So what is composit ..? A composite is a material made from two or more different materials that, when combined, are stronger than those individual materials by themselves.
![](images/week17/001.png)
Concreteis a best example of composites.
Design
Every week when i started do something i tried to do something usefull ans something different,so here i thinked to do smothing usefull in Composit.so i decided to make a Hydroponic Grass Fodder Tray i always want to build the Hydroponics so i decided to make a Tray .
![](images/week17/002.jpg)
I staretd desgin in Rhino with the help of my instructor Rashid.
![](images/week17/003.png)
3D model
Milling and Cutting
For my design i need to make wooden mold of 6 cm thickness , so i used 18mm (1.8 cm) and stacked 4 nos. first i cutted the 18mm plywood sheet into four pieces and glue it together.
![](images/week17/004.jpg)
First i measured the ply-wood based on the design , after ensuring everything is correct , i loaded ply-wood into the shopboat.
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After cutting the required part , i removed the tab's.my instructor Nisam was help me to do these process.
![](images/week17/009.jpg)
Stacking
For the mold i need to put all the 4 pieces into a stack , so here i used Fevicol Synthetic Resin Adhesive wooden glue to make it stack.
![](images/week17/0010.jpg)
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After glued everything stacked 4 pieces togther , my friend Hari was help me to do these process .
![](images/week17/0015.jpg)
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Now I have to put something heavy on the plywoods to stick all the layers well. I used a spare transformer and big stone :-) .
![](images/week17/0017.jpg)
![](images/week17/0018.jpg)
After waitng almost 5 hours it's completey stacked togther.now time to mill our mold.
CNC milling
After Stacking the ply-wood , loaded it with it on the shopboat.
![](images/week17/0019.jpg)
![](images/week17/0020.jpg)
befor milling i secured it with in a ply-wood using screws from bottom to top and after i secured playwood with the sacrfical layer on the shopboat.
Milling
![](images/week17/0021.jpg)
After checking everything is fine with the help instructor Rashid ,so i started make tool path using VcarvePro after that started mill using ShopBot CNC.
![](images/week17/0022.jpg)
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After 8 hours milling due to some shopbot machine failure and power failure, milling process was stucked and can't continue mill, i was very frustrated :-/ .after discussing with instructor i decided to stop the milling process.
![](images/week17/0024.jpg)
Now we got the mold , so we can make composite.
Composite
For composite i used Linen Fabric.
![](images/week17/0025.jpg)
First i coverd the mol using Release Film
![](images/week17/0026.jpg)
![](images/week17/0027.jpg)
![](images/week17/0028.jpg)
full coverd, with the help of Relese Film we can peel the composites from the mold easly at last , otherwise it will stuck it on the wooden mold.
Next i cutted Linen and Breating based on the mold shape and length,i used scissors.
![](images/week17/0029.jpg)
![](images/week17/0030.jpg)
Next arranged all the items togther ,the Relese PEEL PLY ..etc
![](images/week17/0031.jpg)
vacuum bag Setup
In our lab we don't have special Vacuum bag, we need to make it using plastic sheet.
![](images/week17/0032.jpg)
![](images/week17/0034.jpg)
Cutted the platic sheet ,based on the required amount sheet i need to make the Vacuum bag, and i used Double sided tape to ensure it's vacuum.
![](images/week17/0033.jpg)
Now Vacuum Bag is completed
Preparing resin
I used Easy Cast Transparent Epoxy Resin and it' having mixing ratio of 100A:50B and the curing time is about 24 hrs.
![](images/week17/0035.jpg)
Mixed both in 100A:50B ration
![](images/week17/0036.jpg)
![](images/week17/0037.jpg)
Making the composites
Here I'll be using 4 layers of linen for the composites
- First painted some resin on top of relesing Flim
- Soaked First layer of Linen in Resin and applied it on the mold
- Added remaining 3 layer Linen one by one after soake it on the resin
- Then i applied "Relese PEEL PLY" on top of the 4th layer Linen
- Then i added "Breating" layer on top of PEEL PLY
- At last i sealed Vacuum bag that we already seted
- I used Vaccum cleaner for maing vacuum in the vacuum bag, it's work perfectly :-)
![](images/week17/0038.jpg)
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here you can see the excess resin on top our Breating layer (black spot) .
![](images/week17/0046.jpg)
Touch-up
After 24-hr i relesed it from the mold and removed Relese Peel and Breathing layer.
![](images/week17/0047.jpg)
![](images/week17/0048.jpg)
I removed the excess Linen from the Composite using bandsaw.
![](images/week17/0049.jpg)
Hero shot
![](images/week17/0050.jpg)
![](images/week17/0051.jpg)
Resource
* Here you can find all the Design files .