Composites

Asssignment:Design and make a 3D mold (~ft2), and produce a fiber composite part in it



Main task for this week asignment is to mix together two or more materials with fiber and make a mold of any designed object in FT^2. So I choosen a simple tea tray design for this. Unfortunately we are not having shopbot machine in our fablab so its difficult to get printed object in ft^2 here. But I completed 3D design and material part.

3D design:Tea tray

Softwares: Blender,Netfab

To design tea tray inside blender first made rough sketch with dimensions;decided to make 30x20x2 cm tea tray. Also its having two handles at both sides of 2x1 size. Inside blender added one cube and given above dimensions to this ;selected scale is as 0.01m. At both sides added 2x1 size handles with cube primitive.



After this arranged handles at the two sides of cube;selected both handles and cube and joined their meshesh with ctrl+J function keys. So now it becomes whole object. So its a final tray design.

To print this on wooden block its need to add bottom for a design, so added one more cube of thickness 6cm.Placed tea tray design on it and with ctrl+j joined them together. So now final design of tea tray with base is ready.Export this in.stl format.



To make this 3d printable open this in Netfab ,autorepair and export as .stl file format.



We not have shopbot at our place but I did toolpath in cut3d software. Imported this in cut3d and under toolpath window created toolpath for this. Go through following image for settings and toolpath .



Go through tool selection and settings here.

Settings:

End mill size: 6mm

Feed rate:20 mm/sec

Spindle speed:12000 r.p.m

Also I referred following links to make toolpaths for shopbot.



Toolpath

3D machining

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Here I used readymade tea tray for molding as we are not have shopbot for printing.But I will try to contact someone to print this.

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Materials:

Cotton
Hydrostone
Fevicol
Cotton bandage patti(Fiber)
Vaseline
Transperent tape



Following steps I did to make this:

Apply transperent tape on tray design then use vaseline (petrolium jelly)to avoid stickiness.



Apply cotton bandage patti on whole tray. Make a mixture of Hydrostone +fevicol+ water in 1:1:6 ratio and apply it on covered bandage patti.



Now cover this with thick layer of cotton strip and apply solution on it again. Do step 2 and 3 once again.



Keep this for drying minimum 11/2 day. I got following tray after this .





Download tea tray file from here:

Tea tray files