Molding and Casting

I decided to create a mold for the Fab Lab Logo

Creating a sketch for the logo

First, I opened the Fab Lab Egypt logo in Adobe Illustrator

Then to acquire a vector image from the PNG file, I chose: Object -> Image Trace -> Make and Expand

Then I removed all other paths other than the logo by using the "Direct Selection Tool"

Then exported the file as a DXF file using File -> Export

Creating the 3D model

In Inventor, I started a new part file then from the Sketch tab, chose Insert->ACAD to import the 2D sketch and then clicking finish.

Then by clicking "Finish Sketch" we exit the sketching mode so that we can now extrude that sketch.

We click on "Extrude" and select the surfaces we want to extrude

Then exported an STL file by clicking File->Export

Preparing for milling

From Modella Player, I open the STL file then clicked on "Rendering" mode for better display

And then by clicking the "Model" button, I was able to change the dimensions for the model.

Then created a new "Roughing" process using a 3mm square tool.

And then another "Finishing" process also using a 3mm square tool

Then used the "Cutting Position" button to move the tool into the appropriate position on the Wax block

I used silicon gun (Caulking gun) as a mold as it was accessible and very cheap and I wanted to see if it can be any good.

The output wasn't that great as it didn't get all the details needed and the repairing silicon wasn't a good choice.

I casted Expoxy into the mold after applying a separation layer

Files