Molding and Casting Assignment Plan

1. Introduction

This document outlines the plan for the molding and casting assignment, covering both group and individual components. The group assignment involves reviewing Safety Data Sheets (SDS), producing test casts, and comparing mold-making processes. The individual assignment focuses on designing and producing a three-part mold and documenting the casting process.

2. Group Assignment

2.1 Review Safety Data Sheets (SDS)

Objective: Review SDS for molding materials (silicone rubber, urethane rubber) and casting materials (epoxy resin, plaster).

Material	Example Product	Hazards	Precautions	First Aid	Disposal
Silicone Rubber	Smooth-On OOMOO 30	Skin/eye irritation; inhalation risk	Gloves, glasses, ventilation	Wash skin; Rinse eyes 15 min	Cure fully, dispose normally
Urethane Rubber	Smooth-On Mold Max 30	Respiratory sensitization	N95 mask, gloves, ventilation	Fresh air; Wash skin	Cure fully, dispose normally
Epoxy Resin	Smooth-On Crystal Clear	Flammable when mixed; irritation	Gloves, glasses, ventilation	Wash skin; Fresh air	Cure fully
Plaster	USG Hydrocal White	Dust irritation	Dust mask, gloves	Wash skin; Rinse eyes	Dispose as solid waste

2.2 Produce Test Casts

Objective: Create test casts using silicone and Metal Molds with epoxy resin and plaster.

Molds: Made a metal Mold 50mmx 50mm x 50mm Mold

Molds: Silicon Mold Diameter 45mm depth 21mm

Casting:

Epoxy resin (2:1 ratio) – cure 24 hours. I used Green Poxy 33 resin and SD4775 epoxy hardner

Plaster (2:1 powder:water) – cure 1 hour.

Comparison:
- Epoxy: Clarity, strength, long cure.
- Plaster: Cheap, easy, brittle.

2.3 Compare Mold-Making Processes

Objective: Compare 3D-printed molds (additive) versus CNC-milled molds (subtractive).

Process	Tool	Material	Pros	Cons	Surface Finish
3D Printing	FDM Printer	PLA	Fast, low cost	Layer lines, needs finishing	Smooth after sanding
CNC Milling	ShopBot CNC	Wax / MDF	Precise, smooth	Slower, material waste	Smooth with minimal work