Molding and Casting
Group assignments
- review the safety data sheets for each of your molding and casting materials,
- then make and compare test casts with each of them
- compare mold making processes
My group assignments
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 toolpath,and use it to cast parts
- extra credit: use more then two mold parts
Have you answered these questions?
- Linked to the group assignment page and reflected on your individual page what you have learned
- Reviewed the safety data sheets for each of your molding and casting materials, then made and compared test casts with each of them
- Documented how you designed and created your 3D mold, including machine settings
- Ensured your mold has smooth surface finish, that does not show the production process (by postprocessing if necessary)
- Shown how you safely made your mold and cast the parts
- Described problems and how you fixed them
- Included your design files and ‘hero shot’ of the mold and the final object
PC working environment
- PC: MacBook Pro(16-inch,2019)
- OS: Sonoma 14.7.2
- Terminal: zsh
hero shot
This week I made the cat paw paw one and did cast resin.
3D data with Fusion360
1.Designing
1.0 Design(Fusion360)
1.1 The Instructor told me that Including a slight taper (draft) in the wax model facilitates mold release.
2.Tool paths
I made toolpath by Fusion360. I made for tow rough toolpath and two finish toolpath.
Setup
- Setup
This time, the origin is selected as the material top left corner.
- Stock setting I revise the all number to 0.
- Post Process (default) and Click OK.
rough toolpath(part-1)
- Choose 3D Pocket Clearing
- Set tool / Feed & Speed
- Tool & edit I measure the mill and edit.
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Multi-Axis(Default)
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Geometry
- Height
- Set Passes and Stock to leave
check the Stock to leave.
- Linking / Leads & Transitions / Ramp
change the Plunge.
- Simulation
Simulation time : 24m Actual time taken : 30m(I wasn't measuring it, so it's not accurate.)
rough toolpath(part-2)
- Choose 2D Pocket
- Set tool / Feed & Speed
- Tool & edit I measure the mill and edit.
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Multi-Axis(Default)
-
Geometry
- Height
- Set Passes and Stock to leave
The checkbox in the blue box must be unchecked.
- Linking / Leads & Transitions / Ramp
change the Plunge.
- Simulation
Simulation time : 1m Actual time taken :3m(I wasn't measuring it, so it's not accurate.)
finishing toolpath(Parallel)
- Choose Parallel
- Set tool / Feed & Speed
- Tool & edit I measure the mill and edit.
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Multi-Axis(Default)
-
Geometry
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Height(Default)
-
Set Passes and Stock to leave
-
Linking / Leads & Transitions / Ramp(Default)
-
Simulation
Simulation time : 11m Actual time taken : 15m(I wasn't measuring it, so it's not accurate.)
finishing toolpath(Contour)
- choose contour
- Set tool / Feed & Speed
- Tool & edit I measure the mill and edit.
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Multi-Axis(Default)
-
Geometry
-
Height(Default)
-
Set Passes and Stock to leave
- Linking / Leads & Transitions / Ramp
- Simulation
Simulation time : 20m Actual time taken : 25m(I wasn't measuring it, so it's not accurate.)
Simulation
Once the toolpath is created, simulate it.
Please check again. Actually, a contact error was displayed at this time. The cause was the short distance between the object and the wall. So I solved the error by widening that narrowed area.
Actions > Simulation
Post
Actions > Post Process
- Post: Roland RML/ roland rml
- Machine type: MDX-40
Export tool path data (rml) for each end mill to be used. The exported data is read by V Panel.
The basic operation of V panel has already been described in week8, so I will skip the details.
Milling Job
I use Roland MDX-40DA and set Molding wax(ferris File-A-Wax). Milling with Rough Tool path by 3mm Flat end mill.
Start Milling by Finish Tool path by 2mm Ball end mill.
Done.
Molding
- Mixed the silicone (KE-17) gently. The sediment was hard and took a long time to mix.
- Measure the silicone.
- Mixed with the curing agent. Mixing ratio of the agent to silicon is 0.5 %.
- Mixed the silicone and curing. (Workable time of KE-17: About 60 mins)
- I used Release agent to make it easier to remove the silicone.
- Gently poured the silicone on to the wax mold.
- About a day later the silicone was removed.
Casting
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I prepare liquid A and the liquid B of polyurethane resin.
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According to the instruction, proper mixture ratio is 1 : 1. So We measured the weight with a digital scale.
- Pour the mix Liquid A + B to silicone mold.
- It began to cure in approximately 180 seconds.
- It seems the mix liquid become hot, during the cure. We wait the silicone mold is cool, and remove the cast resin.
Done!
- I tried to apply a stripper to 1 and 2 but could not clean them up. So I tried it without applying it and it came out clean! That is 3.
datafile
impressions
- I was surprised how much cleaner it came out without the stripper.
- I want to make it with soft materials.