Moulding and Casting
Overview of week
Group Assignment
- Review the safety data sheets for each of our molding and casting materials
- Make and compare test casts with each of them
- Compare printing vs milling molds
Individual Assignment
- Design a mold around the process we'll be using, produce it with a smooth surface finish that does not show the production process, and use it to cast parts.
Individual Assignment :
Hero shot
Moulding and Casting
Moulding
Moulding is a manufacturing process used to shape materials like plastic, metal, or rubber by placing them into a hollow cavity. The material is heated, injected or pressed into the mould, and then cooled to form a solid shape. It is widely used in mass production due to its efficiency and repeatability. The quality of the mould directly affects the accuracy and surface finish of the final product.
Types
Injection moulding
Molten plastic is injected into a mould to form complex plastic parts.
Blow moulding
Used for making hollow plastic parts like bottles using air pressure.
Compression molding
Preheated material is placed into a heated mould and compressed into shape.
Rotational molding
Mould is rotated in multiple axes to coat and form hollow plastic products.
Extrusion moulding
Material is forced through a die to form long shapes like pipes and tubes.
Sand Moulding
Uses sand to create moulds for metal casting (common in foundries)
Vacuum forming
Heated plastic sheet is shaped over a mould using vacuum pressure.
Transfer moulding
Material is heated, then transferred into a mould cavity (used for electronics)
Casting
Casting is a manufacturing process where molten metal is poured into a mould cavity to take its shape upon cooling and solidification. It is one of the oldest and most versatile methods for making complex metal parts.
Types
Sand Casting
Uses a sand-based mould, ideal for large, simple castings and quick production.
Die Casting
Forces molten metal under high pressure into a metal mould for high precision and smooth finishes.
Investment Casting
Involves a wax pattern covered by ceramic, yielding high-detail, intricate parts.
Centrifugal Casting
Rotates the mould to evenly distribute the molten metal, effective for cylindrical parts.
3D Design
Fusion 360
I start my assignment in 3D design, I create the sketc and give the dimensions respectively. For the dimension I using the parametric, if any changes need in future.
Then by using the extruder command I extrude it upto my required lenght which is I set in the parameters
I consider the design rule to do the proper moulding, so I modify the body by using the draft command upto 5 degree on every side.
After whole process it will easy to remove the moulded part from the parent material without damage.
Here we see all my parameters to do the design and will change if any modification needed
For hold the pair material I create one pillar and hole to tightly attach after we import the material into that mould.
Manufacture
After done everything I moved to do gcode so I uses the manufacture section where we can done the milling gcode.
I set the orgin for the tool starting position
Then to set the tool I go into the 3D mill and looking the tool which one be the right one among many other tools.
