Assignments
This week was molding and casting. After machine(such a hectic week), it was refreshing and nice to not have to work under pressure but then the final project knocks on my door
-knock knock,
who's there?
Final Project.
Final Project who?
Your Final Project!!
And I was like damn as 5 weeks were left so this week, I tried to dedicate as much as time as possible for my final project.
Table of Contents
- Group Assigment
- Review the safety data sheets for each of your molding and casting materials
- Make and compare test casts with each of them
- Compare printing vs milling mold
- Individual Assigment
- Design a mold around the process you'll be using, produce it with a smooth surface finish that does not show the production process, and use it to cast parts.
- Final Project Development
Group Assignment
For the group assignment, we You can access the group assignment here
Individual Assignment
I started off by downloading an emoji with glasses on from the internet. Then I used SVG Converter-Online tool to convert the image to svg file. Then I imported that svg file into fusion and then extruded it. Image source
Huge shout out to Mr. Yuichi TAMIYA as in his documentation we found the zip folder to download Modella Player 4. It was in this Google Drive. I downloaded both the Virtual Modella and Modella Player 4 because they will generate the toolpath for cutting my design and simulate it.
Modella Player 4 is a CAM (Computer-Aided Manufacturing) software that converts 3D designs into tool paths for milling machines.
Virtual Modella allows you to simulate the results of your 3D milling projects before actually cutting materials.
- Roughing: The first step where you quickly carve out the rough shape of your design. It’s all about removing big chunks of material to get the basics in place. Precision takes a back seat here, with speed and efficiency being the priority. Picture cutting in cubes or squares, using a 1/8-inch square end mill that makes quick work of the heavy lifting.
- Finishing: Once the rough shape is done, it’s time for the finishing touch. This stage is all about finesse—refining the details, smoothing the surfaces, and ensuring the final dimensions are spot-on. Smaller and finer tools step in here to give your design that professional, polished look that makes all the difference.
- Make sure your model is saved as a STL (.stl) file.
- Click [File] → [Open] and load your STL file.
- Select the correct Modela machine you are using.( SRM-20 in my case). NOTE: If you don’t select the correct machine first, your toolpath settings might be wrong, and it could cause problems during cutting!
- Click [Material] → [Set Material] to ensure you have the correct material (like "Modeling Wax").
- Click [New Process] → [Roughing].
- Select a larger flat endmill( 1/8 inch or 3mm in my case).
Then keep pressing next until you see "save your file as "
- The height above the material where the machine begins its first movement before it starts cutting. I set the Start Height = 0.4 inch (or a little higher, like 0.45 inch for safety).
- Click [Preview] or [Simulate].
Now I am done with creating a toolpath for roughing but I have to do it for finishing too. So just repeat the process but instead of choosing roughing, choose finishing instead and choose R 0.15 ball.
Ooops! Error!!!
Late realization, our design was 2.5 D which is basically extruding directly from a 2d sketch which wouldn't meet the assignment requirements as it requires to produce a cast with a smooth surface. So instead of creating a completely new design i decided to add 2 spheres for my pupils. Thank you Rico san for this major disaster prevention(which is an exageration but still lots of time, energy and material would have gone to waste if he hadn't pointed it out.) These were the images he sent to clarify it to us:
On my previous design only I added a sphere. Go to Create, select Sphere, choose a plane, set the center point, adjust the diameter, and confirm with OK
Reflection
This week !