LESSON TEME: Molding and Casting

  Figure [1] shows a molding shape I made by using silicon for food. This shape is a slime monster which appaers in a TV game "DRAGON QUEST".

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[1] Molding Shape by Using Silicon for Food

Design for Molding Shapes

  I designed the slime monster for molding shape by using Fusion 360 [2]. The carefully point for designing a molding shape is to make inclination for each edge for milling[3]. And also careful the distance of wide space of each object [4]. Figure [5] shows before/after design for considering the inclination and distance. Figure [6] shows the results of milling data on fabmodules. The right one is the hightmap. The cnter one is raugh cut data. The left one is finish cut data.

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[2] Slime Moster Designed by Using CAD
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[3] Incline Every Edges
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[4] Making Enough Wide Space for Milling
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[5] Before/After CAD Design
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[6] Process on Fabmodules

Milling Molding Shape

  I milled a wax by using SRM-20, the milling speed is 20 (mm/s). The endmill size is the followings:
Rough Cut of Front Side Squared Endmill, 3mm diam.
Final Cut of Front Side Squared Endmill, 0.8mm diam.
Rough Cut of Rear Side Rounded Endmill, 2mm diam.
Final Cut of Rear Side Rounded Endmill, 2mm diam
Figure [7] shows an appearance of milling the molding shape on the wax. Figure [8] shows the result of the rough cut and finish cut of front molding shape. I had a mistake to select the endmill for milling the front side of the molding shapse. I used a squred type endmill but it maybe better to select a round type endmill. Figure [9] was the result of using the round type endmill. It seems to be very smooth. the left side of the figure [9] shows rough cut and the right side is the finish cut of rear molding shape.

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[7] Milling WAX
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[8] Rough Cut and Finish Cut of Front Molding Shape
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[9] Rough Cut and Finish Cut of Rear Molding Shape

Pour Silicon into Molding Shapes

  There are two types of silicon lequid A and B shown in the figure [10]. I pick out the silicon A and B with the same quantity. I stired each silicon for a while and then merged the silicon A and B. I also stired the merged silicon for a while and poured it molding shapes. The left side of figure [11] shows the situlation just when I poured silicon into the molding shape The right side one shows the situation one day after I poured. Finally, I got the casting shapes [12].

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[10] Merging Silicons
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[11] Before/After Silicon Situation
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[12] Got Casting Shape!

Casting Slime Jelly

  For separating material, I pasted butter to the casting shapes [13]. Then, I puored gelatin into the casting shape [14]. After 5 hours, I finally got slime monster jelly [15].

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[13] Paste Butter as Separating Material with Casting Shape
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[14] Pouring Gelatin into Casting Shape
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[15] Got Slime Jelly!

Data Files