Read the material safety data sheet (MSDS) and technical data sheet (TDS) for the resins that you're using.
Design and make a 3D mould (~ft2 /30x30cm), and produce a fibre composite part in it.
Learning outcomes:
*Demonstrate workflows used in mould design and construction.
*Select and apply suitable materials and processes to create a composite part.
Have you:
*Shown how you made your mould and created the composite.
*Described problems and how you fixed them.
*Included your design files and ‘hero shot’ photos of the mould and the final part.
*Read and linked to the material safety data sheet (MSDS) and technical data sheet (TDS) for the resins that you're using.
To achieve this challenge I used, resine crystal, fiber glass, vaseline, catalyzer, and a heart mold that I made using the Shopbot machine
Process Description:
I want to make a chest of heart, In order to achieve this challenge I made my mold using the Shop bot machine
I designed the shape of my mold in Adobe Illustrator, then exported as .PDF and started the process with the Shopbot, If you want to know how to use this machine, I recommend you to visit my assignment of week7
I worked with the same milling tool 1/8* Straight
In this case I used wood with 12 mm of thickness
Parameters:
cut speed (mm/s): 60
plunge speed (mm/s): 30
Plunging depth: 2.5
pass: 1.27*40%
spindle speed (RPM): 8000
file units: mm
Number of passes: 6
Allowance Offset of -0.35 mm
I cut two of each one and assembled the mold to give it the height by gluing it with synthetic glue and using quick grips. It is advisable to do it before nightfall so let dry overnight.
At the next day I get this mold.
As you can see at the collage, I achieved to made the chest of heart.
Here I will explain you in detail:
First, I used gloves to protect my hands (DO IT!). I cut a piece of fiber glass, then having all the materials, I started applying vaseline to the mold, as much as possible, it allows you to remove it easily
Then using 105.1g of crystal resin and 48 drops of catalyzer ( always 45% of the resin crystal quantity). I got 107.4 g mixed.
Through this video I will show you how I did then.
*I left a lot of material, I recommend that about 40 g are more than good for the piece I made, which has the following dimensions: thickness: 24; Width: 13 cm and high: 13 cm.
Then I filled the mold that was ready with vaseline.
I put the piece of fiberglass and then the leaves I found on the floor of the yard of Tecsup to give a small detail.
Then the part of the heart (apply vaseline too) and I began to adjust it with the quick grips, to make pressure.
And that's it!
As you see you have to be very fast, because the resin hardens before you know it.
I let it dry one day.
At the next day, was little bit difficult to remove the mold. And I have to use an extra tools to achieve it.
I did it!.
chest of heart
Improving
In order to improve this assignment, I made it using 5 caps of materials:
Materials:
resine crystal
catalyzer
fiber glass
jute
blue fabric
plastic bag
vaseline
heart mold
In order to achieve this challenge:
I cut the blue fabric, jute and fiber glass in squares.
I started applying vaseline to the mold as much as possible.
Then I put a plastic bag layer. To remove the composite easily.
Then using the same quantity as the first try: 105.1g of crystal resin and 48 drops of catalyzer ( always 45% of the resin crystal quantity). I got 107.4 g mixed.
In the resin I was soaking each square of material and putting it to the mold layer by layer, until achieving five layers, two of jute, two of blue fabric and one of fiberglass.
Finally I put the other part of the heart mold.
And my luggage on top to make pressure on the composite work.
For better results, I changed it for heavy packet of brochures.
Result:
I let it dry one day.
At the next day, I removed the mold, it was so easy thanks to the plastic bag layer.
Here you can see:
I did it!.
Recommendations:
When you make your mold try to think to include some curvatures, to remove it better.
Cut the piece of fiber glass with the silhouette of your mold to have a better finish. (And then sanding is not nice, the material that comes out causes your eyes to bite you, that's why I did not do it, one of my colleagues did it before and he recommended me to do not do it, it's hard work, think twice, or protect yourself very well).
Don't forget to be fast.
Conclutions:
Knowing about the composite opens a wide world of posibilities for making creative products, but also it is important to master the techniques in the use of the materials such as the resin and the fiberglass, because they are delicate and if you make a small mistake, it is shown in a flashier way when you finish the production.
