Group Assignment Individual Assignment 3D Design CAM Machining Casting Design Files
Week 13

Molding and Casting

This week focused on learning different molding and casting processes, the materials involved, and safety considerations. The goal was to design a mold, machine it, and cast a part using appropriate materials while ensuring good surface finish and mold behavior.

Hero Shot
3D Model

Learning Objectives

  • Design appropriate objects within the limitations of your process
  • Demonstrate workflows used in mold design, construction and casting
    •

    Assignments

    Group Assignments

  • 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 molds

    Individual Assignments
  • 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.
    •

    Group Assignment

    Group Assignment

    Learning Section

    Individual Assignment

    Design Process - Creating the F-22 Mold in Fusion 360

    Form Modelling
    F22 3D Model
    Mold Render

    CAM - Toolpath Generation in Fusion 360

    Setup Workflow

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Tool Library

    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Importing Tools

    Voronoi 2D and 3D

    Adaptive Toolpath

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Pocket Toolpath

    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Flat Toolpath

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Scallop Toolpath

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    CAM

    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Post Processing

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Machining - Milling the Wax Mold

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Adding Rudde 3D Prints

    Voronoi 2D and 3D
    Voronoi 2D and 3D
    Voronoi 2D and 3D

    Casting - Using Silicone Rubber

    Voronoi 2D and 3D

    Unfortunately my Silicon Compound Mix was wrong and thus my mold has not set yet.

    Design Files

    You can download my design files from below

    • Mold Fusion File

    • Fusion File
    x