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
Individual Assignment
Mold Max 60 Safety DataSheet Review:
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:
Eye Effects: Irritation
Skin Effects: Irritation
Carcinogenicity: None Determined
Mutagenicity: None Determined
Teratogenicity: None Determined
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:
Eye Effects: Irritation
Skin Effects: Irritation
Carcinogenicity: None Determined
Mutagenicity: None Determined
Teratogenicity: None Determined
Smooth-Cast 300 Series Safety DataSheet Review:
Smooth-Cast 305 Part A
Product/Chemical Name: Smooth-Cast 305 Part A:
Hazards Identification
Harmful by inhalation.
Irritating to eyes, respiratory system and skin.
Limited evidence of a carcinogenic effect
Harmful; danger of serious damage to health by prolonged exposure through inhalation 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 - 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.
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:
Acute Inhalation Effects: None Established
Acute Oral Effects: None Established
Reproductive Toxicity: None Established
Mutagenicity: None Established
Teratogenicity: None Established
Sensitization: None Established
Individual Assignment
1.Designing the Mold
This week, I proceeded with the molding and casting process to make the soft gripper. So i decided to work this time with rhino .Rhinoceros 3D, also known as "Rhino 3D", is computer-aided design software. Rhino CAD is used primarily in architectural trades, industrial design and jewellery design.Source. You can download Rhino from HereAfter downloading if you have rhino account you simply login if not then you hve to first create account and login for usage.
Interface of rhino
Here is the gif file of my design that i created in rhino
Design
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 that i used for miling my design
Open .stl file in Modela Player 4
Select the machine that you have in your Lab
Set the Origin
Set the margin from boundary walls by selecting Manualoption
Start a new process, named Roughing
Select Z at the top axis
Select the tool width, 3mm(for roughing)
Set the cutting area by choosing the "Partial" option
Set the "Contour Lines" to Up Cut
Set the "XY Speed" to 24mm/sec
Rename the process accordingly and press the Finish button
Once completed, you can view the toolpath as well by clicking on the button at bottom right
Similiarly add another process for Finishing. But change the tool size to 1mm, Scan lines to X+Y and XY speed to 14mm/sec
Finally press the "Cut" button, now here you may either give the file directly to machine or you can save them as .prn files for later use.
Following are the steps that i followed in the form of video
3. Milling the mold
For miling i used Roland SRM-20
Miling
Here is the video of miling
After completion of miling my design looks like this
After Miling
4.Mold Time
Before starting cast we must take some measurements . we add water to the mold so we can get idea for how much material we needed for my case its 30 gram , after that we add value of 1.5 of material factor material is more desnse than water
Calculation
Here is the complete process that i followed for mold
Material
The above figure is material that i used for molding both part A and Part B in group assignment i menioned about these material and their specification
Glass weight measurment
before puting material into the glass we must calculate the weight of the glass and set weight machine into zero for measuring weight we used digital weight machine, and above figure show the weight of the glass
measurment after adding specific gravity of the material
Adding PartB of the material
Adding PartA of the material
Mixing the material
Filing
After molding design looks like this
After Molding
After Molding
5.Casting Time
After molding the next step is casting for that i follow the same process that i followed for molding except material, for csting i used SORTA- Clear 37 that is silicone mold rubber , given below image of that material
SORTA-clear 37
Both Parts
After casting the design looks like this
After Casting
Another View
In casting there is some unbalance of ratios of both maerial so it not looks perfect yet and not dry properly, So my instructor suggest me to recast it . So very soon my casting version 2 will be released soon:)
It's All About this week You may Download weeks 10 files from here
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