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Week 10

Molding and Casting

Assignment 10

Group Assignment:

This week group assignment is to review the datasheets of the materials we are using in making mold and cast. Below we are sharing some important points after reviewing safety datasheets of Mold Max 60 for molding and Smooth-Cast 305 for casting materials.

  • Mold Max 60 Safety DataSheet Review:

    • Mold Max® 60

    Product/Chemical Name: Mold Max® 60 Part A:

  • Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
  • Inhalation - Remove source(s) of contamination and move victim to fresh air.
  • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
  • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
  • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
  • After first aid, get appropriate in-plant, paramedic, or community medical support.
  • Flash Point - 300 °F
  • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
  • Storage Requirements - Store in cool dry, well-ventilated area
  • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.

    • Toxicological Information:

    Product/Chemical Name: Mold Max® 60 Part B:

  • Hazards Identification
    • Harmful if swallowed.
    • Irritating to eyes, respiratory system and skin.
    • Harmful to aquatic organisms may cause long term adverse effects in the aquatic environment.
  • Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
  • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
  • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
  • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
  • After first aid, get appropriate in-plant, paramedic, or community medical support.
  • Flash Point - 150 °F
  • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
  • Storage Requirements - Store in cool dry, well-ventilated area
  • Protective Clothing/Equipment - Wear chemically protective gloves and aprons to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.

    • Toxicological Information:

    Smooth-Cast 300 Series Safety DataSheet Review:

    Smooth-Cast 305

    Product/Chemical Name: Smooth-Cast 305 Part A:

    Hazards Identification
  • Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
  • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
  • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
  • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
  • After first aid, get appropriate in-plant, paramedic, or community medical support.
  • Flash Point - 262 °F
  • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
  • Storage Requirements - Store in cool dry, well-ventilated area
  • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
    • Toxicological Information:

    Product/Chemical Name: Smooth-Cast 305 Part B:

  • Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
  • Inhalation - Remove source(s) of contamination and move victim to fresh air.
  • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
  • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
  • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
  • After first aid, get appropriate in-plant, paramedic, or community medical support.
  • Flash Point - 262 °F
  • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
  • Storage Requirements - Store in cool dry, well-ventilated area
  • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
    • Toxicological Information:

    Individual Assignment:

    1. Designing the Mold

    This week sounds quite interesting because I have been looking this kind of work at many places but it was first time i myself doing it :D

    First I need to thought about a design and after thinking for some time I remembered the Logo very famous among the people watching Sci-Fi movies. This was from the movie "Batman Vs Superman: Dawn of Justice". For that I took two logos and combined them to make one model. The model as an image looked like the picture given below:

    Image of the model

    For making .svg file and then .stl file, I followed the below mentioned steps:
    Making Model using Photoshop and Inkscape

    After making the .svg file I opened it in Rhino and extruded the curves and made the boundaries as shown below:

    Making the model in Rhino

    2. Using Modela Player 4

    Using .stl files from Rhino in Rolland Modela Player 4, we will generate .prn files for milling through Rolland SRM-20. Following steps will help you in using this software, you can also get help from the video embedded below:

    All the above mentioned steps can be further clarified by watching the video below:


    3. Milling the mold

    After the .prn files were generated I used them in Rolland SRM-20 and started milling the mold from Machinable Wax
  • Steps performed for using the Rolland SRM-20 were same as mentioned in Week4
    • During the milling picture

    Although in first attempt of milling, the mold was quite good but the height of model was not enough, it was very small as shown in the picture below
    First mold after milling with very small model height

    Inorder to correct this mistake, I increased the height of my model and started milling again. The results were satisfactory after the second attempt and can be seen below:
    After Roughing in second attempt

    After Finishing in second attempt

    4. Making the mold

    Now was the time to take some measurements, we will first add water to the mold so that we get to know how much materials we will require to add and make the silicon mold. For that i used the steps shown in the GIF below:

    Steps for taking measurement using water

    Initially I used Smooth-On SORTA-Clear 37, Silicone Mold Rubber to make the mold. Before using it I went throught the paper available inside to see how much ratios of both materials need to be added.

    Smooth-On Silicone Mold Rubber

    Smooth-On Silicone Mold Rubber

    From the instructions given on the paper, I took 100% of part A (Total weight of water measured) and 10% of part B.

    Measuring the materials, part A and part B

    After adding both the parts of material, I started mixing them for 3 to 4 minutes. Then i poured the material in machinable wax mold and filled it completely. The image below shows many bubbles in the silicon material, I was unable to remove them since we couldn't create a proper vacuum mechanism for our lab.

    Mold filled with Rubber Silicon

    Then I left the mold for curing, and when I went back to lab after two days to see how is it? But it had not cured propperly. So I removed the rubber silicon from the mold and proceed for making mold using another material.

    Removing Rubber Silicon

    A possible reason for the problem occured with Sorta-clear can be the inappropriate material ratio used. While making the mixture we went through the instruction sheet available inside. On that sheet there were different ratios mentioned, So instead of selecting 1A:1B I mistakenly selected the ratio of 100A:10B, due to which the mold didn't cured properly even after so many days.

    A possible reason of mistake while making the Sorta-clear mold

    Using Mold Max 60

    After getting failed in first attempt, now I decided to make the mold using Mold Max 60. The mold made out of this material can also be used for metal casting. It means that I can cast it using the metal available in the lab as well.
    Mold Max 60

    Using almost same steps as before, this time I took 100% part A material and 3% part B material and mixed them for 6 to 7 minutes and poured the material into the mold and filled the mold.
    Mold Max 60 material in the Wax mold

    After filling the Wax mold with Mold Max 60, I left it for curing and took the mold out on next day which can be seen below:
    Mold made of Max 60

    5. Casting

    Now I was ready to make the cast of my model, for that I am using "Smooth-On Smooth-Cast 305".
    Casting Material

    Casting Material

    Using the instructions written on the page available inside I made a mix of 1A:1B, which means both parts of material should be in equal proportion. 50% part A and 50% part B of the weight measured by pouring water inside the mold. After mixing it 1 to 2 minutes I filled the mold with it.
  • Make sure to mix and pour this solution while the fan is switched off, otherwise it will harden quickly.
    • Casting Material in mold

    After a few failures and some hardwork, i was finally able to make a proper cast using the molds. The final casting result along with the mold are shown below:
    Final Results

    That's all for week10..
  • All the Files of Week 10 can be downloaded from Here.




    • Creative Commons License
    This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.