Molding & Casting¶
Molding and casting are techniques used in manufacturing to create objects or parts with specific shapes and properties. These processes involve the use of a mold, which is a hollow cavity that replicates the desired shape of the final product.
Group Assignment¶
Each group choose material to make casting. Ew choose a Oatmeal Soap.
Oatmeal Soap¶
To create oatmeal soap through casting, we begin by cutting the soap into small pieces to facilitate quick dissolution. Next, we place the soap in a cup and microwave it for approximately 40 seconds to melt it. Once the soap has melted, we carefully pour it into the desired mold for shaping. It is crucial to prioritize safety by wearing gloves and using aprons as necessary to protect our hands and maintain cleanliness.
Using a cartoon cup for melting the soap is not recommended as it can negatively impact the scent and color of the soap. To ensure better results, it is advisable to use a glass cup, as my colleague did. The use of a glass cup helps maintain the desired scent and color of the soap during the melting process, resulting in a superior final product. For more information, you can visit my colleague Ali Naser’s website here.
Gypsum Material¶
For information about the gypsum material, you can visit my colleague Ali Al-Saegh’s website here.
Resin Material¶
For information about the Resin material, you can visit my colleague Sayed Ali website here.
Individual Assignment¶
For my individual assignment, I created a 3D design and utilized the Monofab Machine to mill the wax material. Afterward, we proceeded with the molding process using silicon. Finally, for casting, we used resin and hardener.
3D Design¶
For the 3D design, Fusion 360 was utilized as the software of choice. During the design process, it was instructed that the gap between components should be larger than 1.5mm to accommodate the 1.6mm width of the ball. Additionally, the design’s height was limited to less than 2cm due to the wax’s slightly larger height. To create the design, a 2D sketch was initially created, followed by the extrusion process to convert it into a 3D model. Finally, the fillet feature was used to achieve smooth edges and transitions in the design.
3D Design File¶
To download 3D design click here to download the STL file. And click here to download the F3D file.
Milling¶
For milling, we utilized the MonoFab machine, and the material chosen for the process was wax. The MonoFab machine is compatible with wax material, which offers several advantages such as availability and recyclability. The machine’s precise milling capabilities allowed us to achieve the desired shape and details in the wax material.
MonoFab Machine¶
The monoFab Machine is a versatile fabrication tool used for various manufacturing processes. It is commonly employed for milling, 3D printing, and other digital fabrication tasks. The machine offers precise control and accuracy, making it suitable for creating intricate designs and prototypes. Its capabilities make it a valuable asset in the field of digital fabrication and rapid prototyping.
How to use MonoFab Machine¶
To begin the milling process, we first transferred the design file to the computer connected to the MonoFab machine. Next,This ensured precise milling and achieved the desired shape and dimensions for the final product. To ensure stability during the milling process, we applied a strip of adhesive tape to the bottom surface of the wax material, securing it firmly in place. Once the wax material was prepared, we carefully inserted it into the MonoFab machine. Then we determined the center position of the wax material by using a roller and measuring the midpoint of the design in terms of width and length. This step ensured accurate alignment of the design on the wax material. Additionally, we determined the appropriate height by setting the drilling technique to penetrate the wax material to the desired depth. With everything in position, we initiated the milling process by starting the machine. The MonoFab machine executed the milling operations based on the design file, resulting in the precise shaping and carving of the wax material according to the specified dimensions. In the following images, you will see how to set up the machine to start the process.
First, we will position the ball at the center of the design, depending on the corner we desire on the wax.
The model size and orientation setting
The type of milling setting
The Create tool path setting
The Preview Results
The perform cutting
Although the gap in the 3D design was not sufficient to accommodate the width of the ball, the resulting outcome was still acceptable. Despite the constraint, the milling process managed to produce a satisfactory result.
This is the details about the ball
Molding¶
For the molding process, gather silicon A, silicon B, milled wax, plastic cups, plastic spoons, tissues, and a small weighing scale. Mix silicon A and silicon B in a 1:1 ratio with 15g each on the milled wax. Stir the mixture for about 40 seconds. Transfer the mixture to a glass, ensuring equal weights of both components. Stir thoroughly for a homogeneous consistency. Place the mixture in the wax and remove any bubbles. Allow approximately 9 hours for the mold to set.
Casting¶
Resin and hardener were used for casting due to their colorless nature, versatility for coloring, and increased rigidity compared to other materials used in the group assignment. The materials/equipment required included a molded piece, resin, hardener, two plastic cups, two spoons, a small weighing scale, tissues, and water/oil color for coloring. The mixture consisted of a 10g resin to 6g hardener ratio. The resin and hardener were mixed in separate cups, stirred together, and a small drop of coloring was added. The mixture was then cast onto the mold and left to solidify. The resin required approximately 36 hours for full curing. Additionally, I utilize leftover materials from my colleagues for the casting process.
