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Commit 5548a79f authored by Mitalee Parikh's avatar Mitalee Parikh
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mc update2

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Molding & Casting
=======================
### Reviewing materials
#Molding & Casting
###Page Summary
1. Reviewing data sheets for each molding and casting materials
2. Designing a 3D mold
3. Creating Toolpaths
4. Milling
5. Casting parts
6. Comparing casts
7. references
8. Design Files
---
1. Reviewing data sheets for each molding and casting materials
---
Materials are available in the lab:
Smooth-on Sorta Clear 37
Smooth Cast 300 and 305
EasyMold Silicon Rubber
EasyMold Silicon Putty
Smooth-on mold release agent
* Smooth-on Sorta Clear 37
* Smooth Cast 300 and 305
* EasyMold Silicon Rubber
* EasyMold Silicon Putty
* Smooth-on mold release agent
#### [Smooth-on Sorta Clear 37](https://www.smooth-on.com/products/sorta-clear-37/)
**[Smooth-on Sorta Clear 37](https://www.smooth-on.com/products/sorta-clear-37/)**
This series of rubbers by Smooth-on are white translucent silicone rubbers that cure at room temperature with negligible shrinkage. They are very versatile because they offer a lot of easy features like:
......@@ -39,7 +50,7 @@ The webpage for [Sorta Clear 37](https://www.smooth-on.com/products/sorta-clear-
Understanding and following this is important to avoid accidents.
[Link to Safety Data Sheet](https://www.smooth-on.com/msds/files/BD_DS_Eco_Equ_EZB_EZS_Psy_MS_OOMOO_Reb_ST_SS_Soma_Sol_Sorta.pdf)
#### [Smooth Cast 300](https://www.smooth-on.com/products/smooth-cast-300/) and [Smooth Cast 305](https://www.smooth-on.com/products/smooth-cast-305/)
**[Smooth Cast 300](https://www.smooth-on.com/products/smooth-cast-300/) and [Smooth Cast 305](https://www.smooth-on.com/products/smooth-cast-305/)**
This series of liquid plastics by Smooth-on are ultra-low viscosity casting resins that yield bright white and virtually bubble free castings. Some important features they offer are:
......@@ -98,14 +109,12 @@ The webpage for EasyMold Silicon Rubber also shares its [technical data sheet](h
This product comes in both liquid form and aerosol. It can be sprayed onto a mold to help release casts from properly prepared models.
[Link to Safety Data Sheet](http://www.smooth-on.com/msds/files/Universal_Mold_Release_Aerosol.pdf)
### Test casts
For my test casts, I made a quick smaller version of the dodecahedron I make later in the weeks assignment.
I made a dodecahedron in rhino and then made it's molds.
###Process
The process of molding and casting goes like this:
![](./images/mc/moldcast.jpg)
So the first task is to design a mold around the object to be cast. The mold design can be in 1, 2 ore more parts depending on the geometry of the object.
2. Designing a 3D mold
---
First made a pentagon, then rotated it along its side at an angle of
116.565. Polar array on all 5 sides. Mirrored horizontally. Oriented
both pieces to match. Put it in a bounding box. Extended the middle
......@@ -116,8 +125,8 @@ and boolean differenced the previous ones.
![](./images/mc/process.gif)
### Toolpaths
3. Creating Toolpaths
---
I used [FabModules](http://fabmodules.org/) to make the roughing and
finishing toolpaths.
......@@ -142,35 +151,31 @@ First I saved the mold as .stl and then in FabModules...
* **Calculate finishing** with above settings and save
Here is a gif that shows process for roughing toolpath calculation
![](./images/mc/roughing.gif)
![](./images/mc/roughing.gif)
This is how the final roughing toolpaths look:
![](./images/mc/roughing.jpg)
![](./images/mc/roughing.jpg)
Here is a gif that shows the difference for finishing toolpath
calculation
![](./images/mc/finishing.gif)
calculation
![](./images/mc/finishing.gif)
This is how the final finishing toolpaths look like:
![](./images/mc/finishing.jpg)
![](./images/mc/finishing.jpg)
### Milling
4. Milling
---
Will do this step when I'm back in the lab.
### Casting
5. Casting parts
---
Will do this step when I'm back in the lab.
#### REferences
Process of making a mold and casting objects:
![](./images/mc/moldcast.jpg)
6. Comparing casts
---
7. References
---
Types of endmills:
![](./images/mc/types.jpg)
......@@ -183,7 +188,8 @@ Drilling vs Milling:
Centering:
![](./images/mc/centering.jpg)
### Files
8. Design Files
---
* [Dodecahedron 3D model](./images/mc/dodecahedron.3dm.zip)
* [STL file](./images/mc/dodecahedronCAM.stl.zip)
* [roughing.rml](./images/mc/roughing.rml.zip)
......
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