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Molding & Casting

Documentation page for creating molds and casted parts using digital fabrication workflows and molding materials.

Assignment

Molding & Casting

Processes

Mold Design + Casting

Software

Fusion 360 / Aspire

Machine

CNC Milling Machine

Goal: Design a 3D mold, machine it using CNC, and cast a final object using molding and casting materials.

🧠 Learning Objectives

  • Understand molding and casting workflows.
  • Design machinable molds using CAD software.
  • Use CNC machining for mold fabrication.
  • Learn safe handling of molding and casting materials.

📋 Assignments

Individual Assignment

  • Design and produce a mold

    Create a 3D mold using CAD and machine it using CNC.

  • Cast final object

    Produce a final cast using molding and casting materials.

Group Assignment

  • Review safety data sheets

    Learn about material handling, mixing ratios, and safety procedures.

🛠️ Tools & Materials

  • Software: Fusion 360 / Aspire / VCarve
  • Machines: CNC Milling Machine
  • Materials: Wax block, silicone rubber, resin, plaster
  • Tools: Mixing cups, gloves, safety glasses, spatulas

📚 Research

Molding and casting is widely used for producing detailed and repeatable parts. The process starts with designing a positive or negative mold, machining it, then pouring casting material into the mold cavity.

Material Purpose
Machinable Wax Creating reusable molds using CNC
Silicone Rubber Flexible mold production
Resin Detailed hard casting
Plaster Low-cost casting material

👥 Group Assignment

During the group assignment, we reviewed safety data sheets and compared molding and casting materials, including mixing ratios, curing times, flexibility, and final finish quality.

Molding materials
Different molding and casting materials used in the lab.
Safety setup
Safety equipment and handling process.

👤 Individual Assignment

For my individual assignment, I designed a custom mold in CAD software and machined it using CNC. After preparing the mold, I mixed and poured the casting material to produce the final object.

  • Designed mold cavity in Fusion 360
  • Prepared toolpaths for CNC machining
  • Machined the wax mold
  • Mixed casting material and poured carefully
  • Waited for curing and demolded the final part

⚙️ Workflow

  1. Design the mold geometry in CAD
  2. Export toolpaths for CNC machining
  3. Machine the mold from wax
  4. Prepare silicone or casting material
  5. Mix materials according to ratio instructions
  6. Pour slowly to reduce air bubbles
  7. Allow curing time
  8. Demold and finish final object

🧩 Mold Design & CNC Machining

CAD Mold Design
3D mold design created in CAD software.
CNC Machined Mold
CNC machining process for wax mold.

Design Tip: Rounded edges and proper draft angles help remove the cast more easily from the mold.

🧪 Casting Process


// Example mixing workflow

1. Measure Part A
2. Measure Part B
3. Mix slowly for 2 minutes
4. Pour carefully into mold
5. Remove air bubbles
6. Wait for curing
7. Demold final object
Casting Pouring
Pouring casting material into mold.
Curing Process
Material curing before demolding.

✅ Results

Final Casted Object
Final casted object after curing.
Finished Molded Part
Cleaned and finished casted part.

⚠️ Issues & Fixes

  • Air bubbles: mixed slowly and poured carefully.
  • Incomplete curing: corrected mixing ratio.
  • Mold tearing: improved wall thickness and draft angle.
  • Surface imperfections: sanded and refined mold surface.

📦 Downloads

Fusion 360 File CNC Toolpaths Process Notes Safety Documentation

Reflection — What I Learned

  • Mold design directly affects final casting quality.
  • Material ratios and curing time are critical.
  • CNC machining enables precise mold fabrication.
  • Careful pouring reduces air bubbles and defects.