Week.12 Molding and Casting

Assignment design a 3D mold, machine it, and cast parts from it

The Player

The idea consisted in reproducing at least one of our Foosball Table Player in the same way Alex Shaub did it for his project.

This is me, scanned with Structure Sensor and fixed with Meshmixer

Model 3D

I prepared a box with a 3mm offset all around the geometry and a 3 mm "stair" for the cuttting plane.

Milling with Monofab SRM-20

I am going to mill my model with a Roland MDX-20 in a block of Wax carving

Roughing

First step for milling is do a roughing part.

Milling Machines Settings
Tools: 1/8 SE 4FL 
LONG ALTIN COATED
3.175 mm square 

XY Speed: 20 mm/sec
Z Speed: 20 mm/sec
Spindle 7000 rpm
Path Interval 0.2 mm
Finish Margin 0.0 mm

Only along to the Y direction which is faster for my geometry

Finishing

First step for milling is do a roughing part.

Milling Machines Settings
Tools: 1/8 SE 4FL 
LONG ALTIN COATED
0.79mm square for the finishing. 
cutting Area:Partial
XY Speed: 20 mm/sec
Z Speed: 20 mm/sec
Spindle 7000 rpm
Path Interval 0.1 mm
Finish Margin 0.0 mm

Only along to the X and Y direction which is more precise for my geometry

The Rolamnd SMR20 milling the wax model

Preparation of the Silicone Mold

For the silicone mold I am going to use the

FormSil 25 Pro /1kg Set.

FormSil 25 Pro is tin-curable silicone rubber to create durable molds. Can be cast or be thickened with a thickener to a thixotropic mass for brush-up molds. Time of approximately 1 hour and a curing time of 5 hours. White

FormSil 25 Pro

Catalizator

Catalizator, to add in a proportion of 3%/ 5%

Mesure how many Marble castin mix you need by a glass of water volume

Vacuu to eliminate all bouble in the mix

pour from above to prevent the formation of bubbles

Silicone for negative mould

The Result

for the final casting I decided to use the MarbleCast Standard

MarbleCast alpha crystaline gypsum standard setting. - Plaster / water ratio: 100/25 to 100/30 - Soaking time: 30 sec - Mechanical mixing time: 1 min - Beginning of set: 10 min - End of set: 13 min - Hardening time: 30 min

Marble Casting

Source 3D Model
Elia Player MeC.stl