Molding and Casting Assignment Plan

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) for molding and casting materials, producing test casts, and comparing mold-making processes. The individual assignment focuses on designing and producing a three-part mold with a smooth surface finish (hiding toolpaths) and casting parts using it. The project demonstrates mastery of molding and casting techniques, integrating digital design and fabrication processes.

2. Group Assignment

Group Assignment Page

Group Assignment Molding and Casting Visit our Week 13 group link

3. Individual Assignment

3.1 Design a Cake Mold

Objective: Design a cake mold for casting casting with candle and with chocolate

  1. Create Master in SolidWorks:
    • Design a 55 mm x 55 mm x 30 mm cube with a 45 mm diameter and depth of 18mm hollow center.
    • Add a 10 mm diameter hole on one side with a couter sunk of 20mm for pouring.

      • Cavity

    • Create a base of 55 mm x 55 mm x 20 mm cube with a 45 mm diameter core and height of 18mm.

      • Core

    • Create a cake of diameter 45mm and a height of 18mm. It should have hollow shells slip five times at a thicknes of 4mm

      • cake
  2. Create Assembly of core and Cavity:
    • Align parts using pins/holes for precise assembly.

      • Assembly
    • Sectioned parts ofethe Assembly to view internal

      • Section plane
  3. Add Sprue and Vent:
    • Include a 10 mm x 20mm contersink diameter sprue channel for resin pouring.
    • Add a 2 mm diameter vent for air escape.

      • Spuce & Vent
  4. Verify:
    • Ensure smooth surfaces and tight tolerances for alignment.
    • Export as STL files: Cake 2.STL, Cavity.STL, Core.STL.

      • Design Files for Download

      Moulding Zip

3.2 Mold Production

  1. 3D Printing:
    • Import STL files into Cura.
    • Settings:
      • Printer: FDM CR.
        • 3D-Printer
      • Material: PLA (1.75 mm).
      • Layer height: 0.1 mm (for smoother surfaces).
      • Infill: 20%.
      • Supports: Not Needed.
      • Build plate adhesion: Brim (5 mm).
    • Slice and export G-code: mold_base.gcode, mold_top.gcode, mold_insert.gcode.
      • Slicer
    • Print time: ~1 hrs 50min 46 sec for all the parts

    2. 3.3 Casting Process

    1. Prepare Mold:
      • Assemble two mold parts, ensuring alignment via pins.
        • Two Halves
      • Secure with tape.
    2. Mix Resin:
      • Mix epoxy resin and hardener (1:1 ratio, per TDS).
      • Work in a well-ventilated area, wearing gloves, safety glasses, and N95 mask (per SDS).
        • Mixing
    3. Cast Part:
      • Pour resin into sprue until mold is filled.
      • Casting Cake
        •
      • Cure for 24 hours at 25°C.
    4. Demolding:
      • Disassemble mold parts carefully.
        • Silicom Mold

    3.4 Design Output

    • 3D Printed PartsCake, Core and cavity
      • Core, cake and cavity
    • Files for Download:

      Zip Files for Downloads

      STL files

4. Reproduction Instructions

  1. Cast Parts:
    • Source epoxy resin, mold release, and safety equipment.

      • Silicon resin and Hardner
    • Cake Mold
    • Casting Candle
  2. Final Product
    • Candle cake from Silicon mold
      • Candle cake

5. Conclusion

The group assignment provides a comprehensive comparison of molding and casting materials and processes, highlighting trade-offs in flexibility, durability, and ease of use. The individual assignment demonstrates mastery of mold design and production, achieving a smooth three-part mold for casting.