8. Cast and Molding¶
This week I worked on designing a shape for keychain and magnet using Fusion 360 and create it using monoFab machine for casting wax, create mold using silicon rubber and use hard material for the final shape (such as soap and resin)
check group page for more information
Cast-Molding Design Tutorial – Parametric Magnet + Keychain batman¶
click here to download .STL file
Choose picture - Refrence¶
Material workspace dimensions¶
The real bed-work in depth of 1.5 cm, length of 14 cm and width of 6 cm
Sketch expected dimensions¶
Import Image to same plane¶
Scale and move¶
Organize¶
Create Shape¶
Create Construction line in the middle to use it as a mirror and start drawing the first point from the interaction
Half of the outline¶
Create Off-set¶
To create outline border
Trim extra¶
Connect lines¶
Mirror¶
Create Honey-Comb pattern¶
Youtube video link Visit tutorial
Create Pattern¶
Choose Polygon¶
Place on origin¶
Add constraint¶
Add construction Line + dimension¶
Check distance¶
Add parameter¶
Extrude 1 – Border outline¶
Extrude 2 – hex + filler bat¶
Extrude 3 – cut hex¶
Pattern - feature¶
Pattern-axis¶
Pattern-layout¶
Shape¶
Adjust¶
Inspect¶
No less than 1 mm
Keychain¶
Add Keyhole¶
Extrude¶
The design need to be flat¶
Scale¶
Check dimensions¶
Place the chain link to the bottom face add enough thickness and width to sustain forces, not break easily and easy to link.
Add chamfer¶
The objective is to create a design can be made by a laser cutter so adding chamfer minimium of 1mm is crucial.
Magnet¶
Sketch¶
Extrude¶
Create outer wall – 1mm¶
Export¶
Different machines use different file format.
How to use Machine ?¶
Use TinkerCad¶
Import¶
Positioning¶
Checking dimension and position object together to implement them in same real bed-work.
Create new STL file¶
Easier to import as one project.
SRP Player – Machine program¶
Import¶
Main Page¶
Finding Origin¶
For origin you should adjust axis to the center of the bed-work it different than CNC and Laser cutter machine as the origin is the corner
Surfacing¶
The wax surface area after melting is not straight therefore is important to use surfacing to ensure the depth of desired design is accurate
Drill-bit¶
Install the suitable drill-bit to enable the machine work and get best result
Start¶
Clear all other files and choose the desired surfacing file
Surfacing - Result¶
Type of milling¶
Choose your preference regarding to your selected design
Create tool path¶
Mold dimensions¶
To present the mold in the program
Create separate pockets¶
Fill important information of the side panel such as drill-bit of each processes because different drill-bit gives different final shape.
Result – Toolpath¶
Cutting¶
Separate each process¶
‘111’ batman and ‘222’ flower is for roughing processes (change drill-bit to 3/32 inch BN), ‘333’ batman and ‘444’ flower for finishing processes (change drill-bit to 1/32‘’ Ball).
Result¶
The mold is paper thin so while cleaning it easily get punctured, also if not punctured it will not carry pouring material such as water and silicon carbide.
## Estimate needed resin weight¶
### Add water¶
### Cleaning-Kit¶
### New platform¶
Using glue gun to connect the wax platform to straight surface that can handle weight easily without problems.
Pouring¶
Add 10 grams to water weight (89 grams + 10 grams == 100 grams of silicon rubber mixture). The recommended ratio is 50:50 ratio between green and clear silicon rubber.