3D-Printed Mold and Composite Panel Documentation

1. Introduction

This document details my design and production of a water jet mold for fabricating a plywood sawdust reinforced composite material made from SR epoxy 33 and SD4775 Hardner. The process integrates computer-aided design (CAD) in SolidWorks and computer-aided Controlled Cuting via CNC water Jet Cutter and composite fabrication, meeting the assignment’s requirement for a digital process not covered in other assignments.

1.1 Purpose

I purpose to design a reusable mold, produce a composite panel using resin and hardner fused with plywood dust from the wood workshop, and provide comprehensive documentation, including safety considerations and reproduction instructions.

1.2 Scope

My project includes:

Designing a 3mm mild steel flat mold (300mm x 300mm x 3mm) using SolidWorks.

Cutting the mold on a water jet cutter

Fabricating a composite panel 270 000mm3 using SR epoxy 33 and SD4775 Hardner fused with plywood sawdust from the wood workshop

I Assembled the Mold

I added Adding the resin

I added added the Hardner

I added Saw Dust

I applied applied Blue seal (petrolim jelly) as a releasing agent

I Mixed the contents together with a wood dowel

I poured the mixture into the mild steel mold

I Reviewed the Safety Data Sheet (SDS) and Technical Data Sheet (TDS) for a generic epoxy resin.

I documented all steps for reproduction.

Calculating Volume300mm x 300mm x 3mm = 270000mm3

1mm3 = 0.001g (according to conversion rate)

270000mm3 x 0.001g = 270g

Ratio:Resin:Hardner; 100:27, Refer to the dadat sheet

Resin:100/127 x 270g = 212g

Hardner:27/127 x 270 = 57.4

Wood saw dustwe put on 5% of wood dust by mass

2. Requirements

2.1 Functional Requirements

Mold:

Dimensions: 300mm x 300mm x 3mm (overall), with a 3mm deep cavity for a flat panel.
Smooth surface for easy demolding.
Compatible with epoxy resin

2.2 Non-Functional Requirements

Leak Tight: Mold must Be tight so that the resin mixture doesn't leak
Material: 3mm mild steel plate with drilled holes to hold the pieces together
Safety: Adhere to SDS guidelines for epoxy resin handling (ventilation, PPE).
Convert to DXF File I Converted the solid works drawing to a dxf file compatible with the water jet cutter

Files for Download:
Zip Files for Downloads
Mold DXF files for Download

2.3 Constraints

Software: Solidwarks licence student version
Hardware: Multicam VSeries water jet cutter
Materials:3mm Mild steel sheet
Time: Design and cutting 3 hrs hours; composite fabrication <6 hours.

3. Safety Data Sheet (SDS) and Technical Data Sheet (TDS) Review

3.1 SDS for Epoxy Resin

Hazards:

Skin/eye irritation (Category 2).
Serious eye damage, Category 1 (Eye Dam. 1, H318).
Skin sensitisation, Category 1 (Skin Sens. 1, H317).
The mixture does not contain substances classified as 'Substances of Very High Concern' (SVHC) >= 0.1% published by the European CHemicals Agency (ECHA) under article 57 of REACH: http://echa.europa.eu/fr/candidate-list-table

Precautions:

I wore gloves, safety glasses, and respiratory protection.

I Worked in a well-ventilated area or use a fume hood.
I Avoided skin contact and washed thoroughly after handling.
I stored resin and hardener at 15–30°C, away from ignition sources.

First Aid:

Skin: Wash with soap and water.
Eyes: Rinse with water for 15 minutes, seek medical attention.
Inhalation: Move to fresh air.

Disposal: Cure excess resin fully before disposing as non-hazardous waste.

3.2 TDS for Epoxy Resin

Mix Ratio:100:27 (resin:hardener by volume).
Cure Time: 6–8 hours at 25°C.
Application: Novel composite

5. Testing and Validation

Mold:

I inspected the composite for smooth surfaces and accurate cavity dimensions.

Test with mold release agent to ensure demolding.

I used vaseline (petrolium jelly) as a releasing agent and it worked

Composite Panel:

Visual: I checked for uniform resin distribution, no voids.

Structural: Verify panel rigidity (manual flex test).

Safety: Confirm compliance with SDS (e.g., no skin contact, proper ventilation).

6. Risks and Mitigation

Risk: Incomplete resin infusion (voids in composite).
- Mitigation: Use heat gun to remove bubles after pouring.
Risk: Resin skin irritation.
- Mitigation: Wear gloves, safety glasses, and work in ventilated area per SDS.

7. Conclusion

This project demonstrates a digital process integrating CAD Solidwarks, CAM Water jet cutting using DXF, and composite fabrication.

Water Jet Cut Mold and Composite Panel Documentation