Task: Design and make a 3D mould, and produce a fibre composite part in it

For this week's assignment I wanted to create something useful for me which I can use and something Innovative.

So for this week's assignment, I decided to created the Mould of the Mask and then use it to create multiple masks. So I came up with the idea of Makerman Mask! Just like a Ironman and batman a Makerman is a superhero which helps Makers in creating their projects!

So now our task is to create 2 things!
1. Create the Mould (Either via 3D printing or via Laser/ CNC Machine).
2. Create the composite (By mixing two or more constituent materials).
3. Apply composite on to the Mould and create the masks.

When you google about the definition of the composites you will get :
A composite material (also called a composition material or shortened to composite which is the common name) is a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components.

Basically it is multi layer material which is super strong, and waterproof as the resin is. Specially these materials are used for building boats, repairing boats, making light weight but super solid things. So, the composite materials may be used to build aircrafts, kayaks, space-shuttles, gliders, armors for vehicles, personal armor and lot more, wherever strength and weight ratio is really crucial.

Step 1 : Creating the rough sketch of What I want to Make. The dimensions are 290mm X 200mm. While measuring the mask I used a ruler to see what will be length of the mask and I found out it was approximately 150mm. So I decided to create the core mask with the length of 150mm. Then I created the eyes of the Makerman! And then I decided to add some funky elements So I can give meaning to the mask. So I added 2 semi circles on both the ends of ear and one Gear on the Head.


Measuring





Sketching




Step 2 : Creating Digital design of my sketch. Due to the easiness and simplicity as well as rapid design creation capability of Tinkercad.com it is becoming my favorite choice. Whenever I want to design less complicated structures. It has lot of build it in shapes and the Maker community is actively sharing the designs on the public platform. So the task gets real easy. After creating the design, I exported the design in to the .svg file. Intentions are to do the cutting using Laser Cutting Machine.





Step 3 : Creating Mould in the Laser cutting machine.
Material used : Acrylic
Machine used : SIL Laser Cutter
Speed : 15
Power : 20











Step 4 : Composite Preparation
About the composites.
1. Resin
2. Hardner
3. Glass Fiber


Process :
1. I took one plastic sheet and then I placed the mask(mold) over it and then I put the Glass fiber on the Mask.
2. After putting the glass fiber I craeted solution of Resin and Hardner (65 Resin and 35 Hardner) Mixing Ratio in a Glass.
Resin : 65
Hardner : 35













Step 5 : Applying composite on to the Mould : After Creating solution in a plastic glass, I used a Brush to apply that solution on the Glass fiber. And After that I waited 6 hours before removing the composities.


Before applying the solution





After applying the solution





Use extra care while applying the solution. Because its very hot and can do reaction with the skin. Wear gloves and avoid the direct contact.




Step 6 : Removing the Mould : I did a mistake. While applying the composites i didnt cut the extra part. And now the composites are hardened and the desired shape is missed. Now either I have to create the New one! Or I can use Grinder to cut the extra part and use the same.

Final :

Download Design Files