I Love Creating Designing Prototyping

Week 12::3D Molding and Casting


Design appropriate objects within the limitations of 3 axis machining:
Because I was used the shoehorn every morning, so I want to make a shoehorn for myself and my friends.

As usual, I use Fusion 360 to draw the shoehorn and use i3 printer to printout.

螢幕快照 2016-04-27 下午8.32.28
Fig1. Fusion 360
螢幕快照 2016-04-27 下午8.33.05
Fig2. Fusion 360
shoehorn
Fig3. Fusion 360

Use 3D printer to printout and use some putty(we called it butterfly) to smooth the surface.

Repeat sanding and use putty to smooth it and repeat.

shoehorn_print
Fig4. 3D printout
shoehorn_print2
Fig5. 3D printout
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Fig6. Putty to smooth the surface
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Fig7. Accelerator for putty
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Fig8. Mixed them
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Fig9. Sanding
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Fig10. After putty it
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Fig11. Varnish panting
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Fig12. Final

But my final project was made a fishing sinker with my fishing float. So finally I am not yet casting shoehorn, but I will do it as soon as possible.

Demonstrate work flows used in mold design, construction and casting:

I used Fusion 360 to draw a fish be a fishing sinker for molding and casting.

Then I used machinable wax、CNC machine to mill my mold.

fish
Fig13. Fusion360 for fish
fish2
Fig14. Fusion360 for fish

For milling machinable wax. The MDX540 variable what is set:

  • 2mm square Milling Cutter
  • Spindle: 8000 RPM
  • Z down position: 7 mm
  • IMG_0395
    Fig15. MDX540 for milling
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    Fig16. MDX540 for milling
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    Fig17. MDX540 for milling
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    Fig18. After milling
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    Fig19. After milling

    Then I used oomoo to make a mold.

    Equal parts oomoo A and B by volume. Then Mix, mix and mix it.

    IMG_0448
    Fig20. Oomoo A and B
    IMG_0453
    Fig21. Oomoo A and B by volume
    IMG_0460
    Fig22. Mix and mix
    IMG_0464
    Fig23. Make a mold
    IMG_0467
    Fig24. Demold in 75 minutes
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    Fig25. Demold
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    Fig26. Fix the mold
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    Fig27. Fix the mold

    JC told me how to melt down alloy and I used two pieces of MDF and metal clamp to fix the mold. Pouring of the liquid metal into my mold.

    IMG_0536
    Fig28. Pouring into mold
    IMG_0542
    IMG_0551
    Fig29. Result

    Try to make another mold with silicon.

    IMG_0572
    IMG_0576
    IMG_0615
    IMG_0629
    IMG_0650
    IMG_0643

    To cut the mold into two symmetric pieces.

    IMG_0659
    Source Files:

  • fish.stl
  • fish.f3d
  • shoehorn.stl
  • shoehorn.f3d
  • shoehorn.gcode