Molding and Casting

Group Assignment

The group assignment involved reviewing safety data sheets for various molding and casting materials, conducting test casts, and comparing the process of printing versus milling molds.

Material 1: Gypsum

  • Safety precautions: Wear eye protection and gloves, avoid inhaling dust.
  • Mixing ratio: 2 parts water to 3 parts gypsum.
  • Work time: About 10 minutes, depending on factors like temperature.
  • Cure time: Typically 30-60 minutes.
  • Result: Versatile material with relatively short curing times, but requires careful handling to avoid air bubbles.

Material 2: Mold Max 60

  • Safety precautions: Wear appropriate PPE, ensure ventilation.
  • Mixing ratio: 100A to 3B by weight.
  • Work time: 45 minutes.
  • Cure time: 24 hours.
  • Result: Flexible silicone mold rubber suitable for various applications, with minimal shrinkage.

Material 3: Smooth-Cast 305

  • Safety precautions: Wear appropriate PPE, ensure ventilation.
  • Mixing ratio: 1:1 by volume.
  • Work time: 2.5 minutes.
  • Cure time: 10 minutes.
  • Result: Quick-setting resin ideal for rapid prototyping, requiring careful mixing and handling due to its fast curing process.

Printing vs Milling Molds

  • Printing: Takes approximately 2 hours, with high accuracy and resolution suitable for intricate designs.
  • Milling: Takes about 30 minutes, offering excellent precision and accuracy for functional prototypes.

Overall, each material and technique have their advantages and considerations, making them suitable for different applications and preferences.

Individual Assignment

Real Madrid Logo Casting Project

In celebration of Real Madrid's victories in the Champions League against Manchester City and Barcelona, I embarked on a molding and casting project to create the iconic Real Madrid logo. This documentation outlines the steps involved in creating replicas of the logo using both 3D printing and casting techniques.

Step 1: 3D Printing To begin the project, I obtained a high-quality 3D model of the Real Madrid logo. Using an SLA 3D printer, I carefully sliced the model and initiated the printing process. The printer deposited resin layer by layer, gradually forming the intricate details of the logo. After approximately 2 hours, the 3D printed logo was complete, boasting a smooth surface finish and high accuracy.

Step 2: Mold Making with Dragon Skin 10 Medium With the 3D printed logo as a master, I proceeded to create a mold using Dragon Skin 10 Medium, a flexible silicone mold rubber. Following safety precautions and manufacturer guidelines, I weighed and mixed the silicone components in the correct ratio (100A:10B) and thoroughly stirred until uniform. I then poured the silicone mixture over the 3D printed logo, ensuring complete coverage and allowing it to cure for 24 hours.

Step 3: Casting with Smooth-Cast 305 Once the silicone mold was fully cured, I carefully demolded the 3D printed logo, revealing a detailed negative impression within the silicone mold. To create replicas of the logo, I chose Smooth-Cast 305, a quick-setting polyurethane casting resin. Following safety protocols, I measured equal parts of resin and hardener, mixed them vigorously for 30 seconds, and poured the mixture into the silicone mold. With a short work time of 2.5 minutes and a cure time of 10 minutes, the casting process was swift yet required precision in mixing and pouring to avoid defects.

Step 4: Final Result After allowing the Smooth-Cast 305 to cure fully, I carefully removed the cast replica from the silicone mold. The result was a solid, white replica of the Real Madrid logo, capturing all the intricate details and contours of the original 3D printed model. The casting process provided a faithful reproduction of the logo, showcasing its versatility and suitability for rapid prototyping.

Conclusion: The molding and casting project enabled me to create accurate replicas of the Real Madrid logo, paying homage to the team's victories in the Champions League. By combining 3D printing with silicone molding and polyurethane casting, I was able to produce multiple copies of the logo with ease and efficiency. This project demonstrates the versatility of molding and casting techniques in replicating complex designs and celebrates the spirit of innovation in both sports and fabrication.