Week 11

Composites

Assignment -  to design and make a 3D mold and create a fibre  composite

I decided to make a tray using and thought this was a good opportunity to start by practicing my Rhino CAD skills. I really want to get good at this!  After following several tutorials and with advice from our tutor Joel I made a two part mold with register holes for 6mm dowel, see below.

Rhino files for tray
 tray_small
tray_top
 

Next to use the shopbot to make the mold. See the shopbot details below, 6mm end mill cutting foam, 12000 speed

I was really pleased with the results, a good finish, see above the results from the first rough cut and then the final cut.

Next to prepare the mold I covered it with vaseline to help remove the cast after it has dried overnight and also cut the hussein up into

thin strips. I used the Smooth cast below in equal parts and stirred well. It's messy so be prepared especially when making a 2 part mold!
It seeps out in a guey mess!

Making preparations below for the mold and using hussein strips

Below the hessien in criss-cross fashion to strengthen the composite having been soaked
in the resin. I then added the 2nd part of the mold and fixed both sides in place with dowel through
the 4 register holes

The two part mold in action held together with 4 grips hopefully tight enough
but not too tight in case the foam mold becomes distorted. I left it over night