16. Molding and casting

Class

Assignment

individual assignment:
design a mold around the stock and tooling that you’ll be using,
mill it (rough cut + (at least) three-axis finish cut),
and use it to cast parts
group assignment:
review the safety data sheets for each of your molding and casting materials,
then make and compare test casts with each of them

Previous year

Assesment

Learning outcomes

  • Design appropriate objects within the limitations of 3 axis machining
  • Demonstrate workflows used in mould design, construction and casting

Have you?

  • Explained how you designed your 3D mould and created your rough and finish toolpaths for machining
  • Shown how you made your mould and cast the parts
  • Described problems and how you fixed them
  • Included your design files and ‘hero shot’ photos of the mould and the final object
  • Reviewed the safety data sheets for each of your molding and casting materials, then made and compared test casts with each of them

Evaluation

  • Global evaluation > Assigned > pending

Schedule

weekly global open lab

  • Saturday 9:00A EDT
  • 10:00PM JST
  • http://fab.academany.org/2020/mcu.html
  • password: 1234
  • purpose
  • Final project の相談

post-schedule meetings

  • date to be confirmed each week
  • ex. June 10,June 17,…
  • purpose
  • complete random review
  • check-in on progress, issues
  • final project presentations

Cut Off date:ドキュメントの最終締め切り

  • based on progress
  • TBA: project presentations

What to do after Lab open

  • mill pcb
  • input week
  • output week

  • networking week

  • milling wax

  • molding and casting

  • group assignment

  • input week: Oscilloscope and probe an input device(s)’s analog and digital signals.

  • output weel: Measure the power consumption of an output device

  • wild card week

  • final project

To Do

Flow

Tools and material

No. Type
CU 130007 0.0625” DIA 2FL SE AlTiN 1/16
CU 136596 0.1250” DIA 4FL SE LONG AlTiN 1/8
CU 132075 0.0625” DIA 2FL BALLNOSE AlTiN 1/16
CU 137212 0.1250” DIA 4FL BALLNOSE LONG AlTiN 1/8

note: machinable wax is made of wax and polyethylene powder

Size

  • MDX-15 work area: 152.4mm(X)×101.6mm(Y)×60.5mm(Z)
  • Machinable wax: 152mmx92mmx39mm -> 実際は小さかった
  • Endmill
    • 0.1250” DIA 4FL SE LONG AlTiN 1/8
    • Size: 1/8”=3.175mm
    • OverAll Length: 2-1/4”(2.25”) =57.15mm
    • 0.0625” DIA 2FL SE AlTiN 1/16
    • Size: 1/16” =1.5875mm
    • OverAll Length: 1-1/2”(1.5”) =38.1mm

Design to think…

  • XY size: wax > 152(X)mmx92(Y)mm
  • Final Part size: wax - wallx2
  • depth Z: 1.5 in mill > 38.1 -　10mm?_collet
  • distance between bumps凸 & dents凹: tool size > 1.58mm(1/16”) > 0.79mm(1/32”)
  • Registration Key, Registration post

Material

  • wax x 1

Process

  • 3D modeling
    • Fusion360
  • Tool Path
    • Modela Player4
    • Virtual Modela
    • my site
    • Rough cut (1/8”)
    • Finish cut(1/16”)
  • Casting
    • negative silicone rubber mold
    • material
    • positive resin cast
    • material
    • color

Shanghai Local session Video
Mold Rubber Hardness video

Install (Windows)

Modela Player 4

Virtual MODElA

両面切削マニュアル(SRM-20 with MODELA Player4)

group assignment

safety data sheet
- 2019 local session

Next week

  • Monday Recitation 23:00-24:00
    • startups or machines
  • Tuesday Asian Regional Review
    • 12:00
      • zoom http://fab.academany.org/2020/video.html
    • 21:00
      • zoom http://fab.academany.org/2020/meetings.html
    • pw:1234

  • Wendnesday Class 22:00-1:00

    • Wildcard Week
    • assignment Design and produce something with a digital fabrication process
      (incorporating computer-aided design and manufacturing) not covered
      in another assignment, documenting the requirements that your
      assignment meets, and including everything necessary to reproduce
      it. Possibilities include (but are not limited to) composites, textiles, biotechnology, robotics, folding, and cooking.

  • Neil gives tour of ~10 topics