Fusion360 design file of Miramare castle in a wax mold

Group assignment page

What I learned

SmoothCast 305, the casting material, poses several safety risks. It is potentially carcinogenic, can cause allergic reactions, severe skin irritation (especially due to heat generated during mixing), respiratory issues if inhaled, and may lead to organ damage. It is also hazardous to aquatic life and must not be disposed of down drains. The material should always be handled in a well-ventilated area with gloves to prevent burns from the reactive A:B mixture. Technically, SmoothCast 305 is mixed at a 100A:90B weight ratio, with a 7-minute pot life (time available to mix and pour) and a 30-minute cure time. Once cured, the solid product is white.

Mold Star™ 16 FAST, used for molding, does not carry any official hazard statements but still requires basic first aid precautions. In the event of inhalation, the person should be moved to fresh air. For eye contact, rinse thoroughly with water for 15 minutes and consult a physician. Skin contact should be cleaned with soap and water, and for ingestion, the mouth should be rinsed. This material has a 1A:1B weight ratio, a 6-minute pot life, and also cures in 30 minutes. The final solid form is blue-green.

Design

At first, I wanted to make a relief map like this one. This represents a form of cultural expression for me. However, I realized that a relief map would be much too complicated for a CNC machine.

However, I scaled the model down for scale to the wax mold, in case I ever wanted to use another form of creating a cast rather than CNC. It's about 4" long.

I thought making something blocky like a castle may be more within my limitations. I decided to replicate this more complicated Miramare castle design but make it way more simple with no overhangs (can't have any overhangs in the design, otherwise, we couldn't pull the cast).

The finished floor plan.

The basic shape of the castle.

Replicating the differences in height of the castle roof (ex. the castle has 2 small towers which I made 1 inch tall).

The castle in the 7x3x1.5 wax block! However, my instructor told me this was still too complex for the CNC mill, which I found surprising. However, SLA printing is still a possibility. I was not able to book an appointment this week, I will resolve this problem by finishing the cast in the next 1-2 days.