13. molding and casting
I have recently been working on different projects that require molds. I will show you the different approaches and steps I've taken to create molds for each of these final products.
Water Bird Whistle
I'm currently working on the development of three musical toys that mimic the sound mechanisms of different animals. For the bird toy, we opted for ceramics due to its intricate internal structure. However, creating this structure with traditional ceramic molds would be challenging. To overcome this, we decided to utilize 3D printing to create cookie-cutter-like molds. This approach ensured uniformity in production. Here are the steps we followed:
Modelling in Rhino
To begin, the 3 molds needed were modelled in Rhino. The first mold was designed to cut the outline of the bird and mark the internal structure as a guide.
The second mold was intended for engraving the eye and the wing.
Lastly, the third mold was created for engraving the logo.
3D printing
Afterward, these files were exported in an STL format and then 3D printed.
Manufacturing
Firstly, the ceramic paste was prepared and rolled out. Using the cutter, the outline was then carefully cut.
Next, the internal structure was engraved, allowing for the construction of the walls and inside structure.
Finally, another outline was cut and pasted on top to complete the piece.
Afterwards, the pieces were left to dry, and once dry, they were subjected to the first firing.
Ceramic Lamp
Modelling in Rhino
This model was quite straightforward. I created two spheres and flattened the bottom one to ensure that the lamp would be able to stand securely without toppling over.
3D printing
Afterwards, I exported the file in an STL format and proceeded to 3D print it. Once the printing was completed, I sanded the entire surface to ensure that the 3D printing lines wouldn't transfer onto the plaster mold.
Making the mold
To begin, I created a box and covered the edges with clay to prevent the plaster from spilling out of the mold when making it.
Next, I started covering half of the 3D printed piece with clay, leaving a 5 cm margin on each side of the model.
Once everything was completed, I added a truncated cone on the top where the casting material will be poured.
Lastly, I inserted the prepared piece into the box, ready to pour the plaster.
Production
Resin ring
Modelling in Fusion 360
1:
paso 1
2:
paso 2
3:
paso 3
4:
paso 4
5:
paso 5
6:
paso 6
7:
paso 7
8:
paso 8
9:
paso 9
