week 14

you can download the rar file with the files compressed in clicking here

Design and fabricate a 3D mold and produce a fiber composite part in it

for this week assignment i want to make a boomerang

first i will design the boomerang in autocad taking as reference the photo of the red and yellow boomerang

you can review my week two 2d design assignment page clicking here

after i design the shape in 2D i will make the object in solid works making the extrusion and rounding the sides

finaly i get the stl of the boomerang

Boomerang by xperex on Sketchfab

in thinkercad i will use the model of the boomerang to get the shape of the mold i am sure that we can make this task in solid works but honestly i don know how to do it, for me is easyer to make it in thinkercad

as i show in the pictures i add a square shape and the model of the boomerang in the same object, i make the boomerang hollow to cut its shape from the square part, once i get the mold i save it as stl and i open it in cura to make sure that the bottom of the mold was in the correct side i save it and i open it in aspire to make the toolpath for the cnc router to machine the mold in MDF.

Boomerang mold by xperex on Sketchfab

i open the stl file in aspire and i configure all the parameters as i did for cutting my closet in week 7 assignment

you can review the week 7 assignment clicking here

here is a video of the cnc milling process

once i had the mold i add demolding wax to the shape

i cut the fiber glass in small squares to easily add them in to the mold. i add a resin layer to begin the boomerang and have a shiny texture, i add a fiberglass layer to give structural fore to the object i continue doing that until i finish the boomerang i use the same resin that i used in the molding an casting assignment

you can review the molding an casting week clicking here

i add a bag filled with sand to make pressure against the mold and make the resin bubbles come out from the boomerang

after the resin dries i sand paper the boomerang to give it a good polished finish at the bottom and i painted it. i use a green marker to draw lines and then i use yellow spray to finish the paint and make the marker paint mix with the spray one.

ATENTION¡¡¡¡¡¡¡¡¡¡¡¡¡¡ it is really important to know the characteristics of the materials that we use and know the toxicity and the important safety measures to take, the fiber glass is really toxic and dangerous, it can cause lung disease if it is breathed, the most dangerous is the fiber glass dust so every time we sand or cut the fiber glass we have to be careful with the dust. in my case i collect all the dust and i add resin to encapsulate it at the end of the work. i also wear latex gloves a mask and protection glasses.

i will add the datasheet of the resin and the fiber glass that i use to consider the danger

week fourteen

composites

Carlos Pérez Ramírez