Assignment
Make a 3D mold and produce a fiber composite part in it.
For this week assignment, I have decided to make a key and coin holder so I can empty my pockets when I arrive home.
I have made a basic prism shape design with two compartments using Rhinoceros.
I have exported the drawing as a stl. file and I have generated the toolpaths used by the CNC milling machine in Aspire.
I have generated three toolpaths
-3D roughing toolpath for a 6 mm foam tool.
-3D finishing toolpath for a 3 mm ball nose tool.
-Profile toolpath for a 3 mm tool.
To make the final composite piece I use Resoltech 1040T epoxy with Resoltech 1048N hardener as matrix ( http://www.resoltech.com/IMG/pdf/DS-1040-1045N-1048N.pdf
), and linen as fiber.
I vacuum bagging my piece along with the piece of one of my classmates.
We had some problems with the airtight of the bag. We were not able to prevent leakage and decided to fix it by putting the first bag in a new one.
Once solved the problem I discovered that the extruded polystyrene foam (XPS) is not the best material to build a female mold. When the atmospheric pressure began to climb the mould started to deform itself in all directions.
After curing for 24 hours I opened the bag and unmold the piece. Here we can see the final deformation of the mould, not only on the sides but also at the bottom.
The final result:
Final files:
- keycoinholder.stl
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