Molding and casting

What is the assignment ?

In this week we have to design a 3D mold around the stock and tooling that you’ll be using, machine it, and use it to cast parts

the goal’s

to make my final project logo.

- Molding and casting

this week we learned how to cast and the steps that we must follow to cast anything. I wanted to cast something easy to learn more about casting. So I thought of making the logo of my final project. So first I designed the logo using fusion 360. designing the logo was easy because I have it in my mind before. one thing I want to add if you want to extrude the text after you write what you want to click right click on the text and click on explode. This will allow you to extrude.

Casting2 by Eidha--Alrashdi on Sketchfab

Then I went to the CNC which is Roland, the same CNC I used in week 5,7 and I used Srp player. I fixed the wax on the bed by using double face tape also there was to lines represent the X-Y.



I didn’t know how to use this software so Carl helped me. We figured out how to use it. so the first step is to add the design which should be as .stl format. Then open it in the software.

In adding the tool I took a flat end tool from the lab then I added it to the software by taking the measurement. (note: I changed the name of the tool later to eidha tool2)

Then I choose the side to know which axis is the length and which is the width also I added the length width and thickness. You must put the Z-axis lower than 60 to be able to change to another angel. After deciding the angle I correct the Z-axis back to its original size later by clicking on 1/1 scale.

The next step is to decide the type of milling. SO since my design is not very complicated I chose faster cutting because its ok for my design and will not ruin it. Then I chose the model with many flat planes because my design doesn't have curved surface. Also since my design is one side I chose cut top only.

In this step, I chose the type of material which id wax. Here I but exactly the same number, for now, but the same numbers then you can modify them after calculating by clicking edit. When I clicked edit I found roughing and finishing. I Click the plus and then clicked on ALL and edit the value by changing from all to partial then apply. I put these values because my reference point is in the middle so I divided the real dimension by two so one will be on the negative side and one in the positive. I did the same with finishing and clicked apply.







Below is the image of speed and feed. In Roughing I put the finish margin 0.2mm this means that the CNC will keep 0.2mm, for example, if I want to cut 1mm and I put the finish margin 0.2mm the CNC will cut only 0.8mm. In finishing I put the cutting-in Amount 0.2 mm to take the remaining from roughing. Also, we make the feed rate in finishing slower than roughing but the spindle rotation higher. To make sure that we took all the material with a very small tolerance. Thanks to Abdullah he told me this.

After that, I change the tool to mine by clicking on (Flat). Since the tool diameter is 3mm I made the font bigger than the tool to fit it in.(note: for the roughing and finishing I used the same the tool.)

Then I clicked calculate tool path to see the borders.

After that in step four, I clicked on the preview to see how the cut part will be also to see how long it will take. In the last step I clicked on the button (output the file) because I want the two files into the panel then I clicked start cutting to save the files.

Then I opened Vpanel and setup the x,y,z. The X,y to the middle because its the origin point.

Then I started cutting after 7 seconds the CNC stopped because he spindle took a big amount of material. THen I knew that the zero of the z-axis were below the surface by 4mm, this means when it started it moved down 4mm and start moving in X and Y axis which will be hard for the spindle. I must say that I ware mistaken by making the logo deeper because it took time to mill is also the tool hit the edges because of its deep for the tool.

Then I went to put the casting. I used SORTA-CLear37. The Technical Data sheet helped me to know the ratio of A and B also the color pigment. After testing with Wendy, we decided to go with weight because measuring with volume is difficult and waste material. SORTA-Clear37 in the data sheet it says to measure with volume, but the container says use volume or wieght which are the same. First I use 65.2g this means 32.6g from part B first then part A and mix them quickly because I must make it before 8 minutes (I will not depend on what is written in the data sheet for pot life becuase the tests show us that it is shorter) also gently to avoid the bubbles. ( I moved it quickly so it generates lots of bubbles and I will not do that again). Wendy plays a game with us to get accurate when measuring with our eyes. We played this game on laser cutting week on cardboard and acrylic. We guessed the volume and I had to mix it three times becuase my guessing wasn't close. I was much better when guessing the Smootcast. Too be more accurate, we can put sand or rice then to take it and measure it. Or calculating in fusion 360.



After one day I came and took the resin out. Then I decided with Wendy to choose red and white for the logo. So I started with the red I put until it reaches the top of the laters then white color to the surface. First, for the red I took 10g from B then I mix it then little amount from the color because it must be around 0.1% to 3% from the resin white then I mix it then I added Part A with 11.5g a mix them all together. After I waited for 25 minutes then I did the same to put white resin. I had no waste - we pour extra mix into Hashim's mold from fab academy.







Finally, I have the first logo I liked the idea of using different colors. There were some bubbles because I didn't mix it gently but overall I liked the logo.

My Experince

This week was amazing it wasn't hard. I didn't do casting on my life and now I know the principle of doing one side and I will aim to do two sides in the future. I thing he next time I will not make the design deeper than I want to nor wast time.

Previous week Home Next week