I Love Creating Designing Prototyping

Week 14::Composites


Demonstrate work flows used in mould design and construction:

The weather has been very hot lately in Taiwan. So this week I want to make a hat with composites for myself.

I used Fusion360 to design my hat like a cowboy hat. I think it very cool.

3d-1
Fig1. Fusion360
3d-2
Fig2. Fusion360

Because FabLab Taipei CNC machine can be milling workpiece z-axis by 15mm. So I separate my hat for two part. Each part for 15mm. Then foam for milling mold with MDX450.

slices
Fig3. Slices
sclices-1
Fig4. Part1
sclices-2
Fig5. Part2
IMG_9632
Fig6. Foam

For milling form for mold. The MDX540 variable what is set:

  • 4mm square Milling Cutter
  • Spindle: 8000 RPM
  • Z down position: 15mm
  • IMG_9640
    Fig7. 4mm square Milling Cutter
    IMG_9654
    Fig8. Milling with MDX540
    IMG_9668
    Fig9. Milling with MDX540
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    Fig10. Milling second part with MDX540
    IMG_9705
    Fig11. Finished milling second part
    IMG_9707
    Fig12. Finished milling second part

    Combination of two parts with broken cutter.

    IMG_9714
    Fig13. Combination
    IMG_9711
    Fig14. Combination
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    Fig15. Combination
    Select and apply suitable materials and processes to create a composite part:

    I was selected old fashion cloth and old underwear to create a composite.

    IMG_9725
    Fig16. Materials

    I used plastic bag for mold release.

    IMG_9728
    Fig17. Plastic bag cover
    IMG_9732
    Fig18. Plastic bag cover

    Put one old cloth and two underwear.

    IMG_9733
    IMG_9740
    IMG_9741

    Put on epoxy (proportion 1:3) .

    IMG_9745
    IMG_9747

    Then I put it into a vacuum bag and used vacuum cleaner to vacuum it.

    IMG_9749
    IMG_9751
    IMG_9752
    IMG_9756

    After 24 hours to unpack it and the result was pretty good. I like it.

    IMG_9787
    IMG_9795
    IMG_9789

    Release the mold with plastic bag.

    IMG_9797
    IMG_9799

    Finall I saw my cowboy composite hat!!!

    IMG_9806
    IMG_9807
    IMG_9809
    IMG_9812
    Source Files:

  • hat.stl
  • hat.f3d
  • hat_up.stl
  • hat_down.stl