Digital Fabrication Studio 0.3 Molding and Casting
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This document discusses molding and casting processes and materials. It begins by describing different types of molds, such as one-sided and two-sided molds, and considerations for each like the material and object shape. Next, it covers designing molds with CAD software and milling molds from materials like modeling wax. Finally, it summarizes the casting process of mixing materials, pouring them into molds, allowing them to cure, and demolding the final objects. Examples are provided of molds and castings for relief sculptures and three-dimensional objects.
Digital Fabrication Studio 0.3 Molding and Casting
- 1. Digital_Fabrication_Studio.07 Molding & Casting –materials,fnishes, processes Massimo Menichinelli [email protected] @openp2pdesign http://www.slideshare.net/openp2pdesign
- 2. Today: * Mold * Designing a mold * Casting into a mold
- 3. 01. Mold: what can you get out of it?
- 4. DIY Blow Molding Gun Source: https://vimeo.com/12940879 http://www.core77.com/blog/object_culture/george_feredays_personal_blow_molding_gun__16846.asp Frustrated by the limited access to plastic blow-moulding equipment, George Fereday developed his own, outftting a standard 'mastic gun'.
- 5. Brickarms: hacking and casting LEGO toys Source: http://www.brickarms.com/ BrickArms offers building toy-compatible custom weapons, weapons packs, and custom minifgs.
- 6. Brickarms: hacking and casting LEGO toys Source: http://www.flickr.com/photos/enigmabadger/4149563340/in/photostream A set of pieces.
- 7. Brickarms: hacking and casting LEGO toys Source: http://www.flickr.com/photos/enigmabadger/4335841517/in/photostream The two-side mold (for injection moulding).
- 8. Brickarms: hacking and casting LEGO toys Source: http://www.flickr.com/photos/enigmabadger/4864781771/in/photostream The two-side mold (for injection moulding).
- 9. Brickarms: hacking and casting LEGO toys Source: http://www.flickr.com/photos/enigmabadger/3643236010/in/photostream Do you know this guy? (Here's the answer)
- 10. Brickarms: hacking and casting LEGO toys Source: http://www.flickr.com/photos/enigmabadger/6174048858/in/photostream Do you know this guy? (Here's the answer)
- 11. BrickForge: hacking and casting LEGO toys Source: http://www.brickforge.com/ http://blog.makezine.com/2011/10/12/make-interviews-indie-lego-molder-brickforge/ “We consider ourselves intermediaries between the community and the lumbering Danish company.”
- 12. BrickForge: hacking and casting LEGO toys Source: http://www.brickforge.com/store/product.php?productid=17777&cat=0&page= (Almost) anything that you cannot fnd in a LEGO store...
- 13. BrickForge: hacking and casting LEGO toys Source: http://www.flickr.com/photos/42832748@N05/5680269752/in/photostream (Almost) anything that you cannot fnd in a LEGO store...
- 14. Few insights about their process Having designed the element how do you create the mold? Once the element is designed a mold is created out of aluminum stock using a CNC milling machine. Most of the time we bundle several accessories together on the same aluminum block. In dealing with such small scale elements we need to insure that every detail is accurate up to 1/10 of a millimeter! I assume you use ABS. When you get it, in what sort of form does it arrive? Once the aluminum mold is created it is slotted inside an injection machine and the magic begins. ABS pellets are mixed with a dye and then poured into a hopper. A heating cylinder and reciprocating screw located inside the injection machine feeds the molten ABS into the mold via gates and channels, that then defnes the fnal shape of the object. Source: http://blog.makezine.com/2011/10/12/make-interviews-indie-lego-molder-brickforge/
- 15. BrickForge: hacking and casting LEGO toys Source: http://www.brickforge.com/store/product.php?productid=17563&cat=462&page=1= You can be even creative and play with the materials and their attached meanings...
- 16. BrickForge: hacking and casting LEGO toys Source: http://www.brickforge.com/?p=636 I mean, really creative....
- 17. BrickForge: hacking and casting LEGO toys Source: http://www.flickr.com/photos/42832748@N05/6030380030/in/photostream I mean, really creative....
- 18. … and what can I do with these toys? Source: http://youtu.be/XtkHygcTC8A And then the fake trailer is so popular, that fans make even a Lego version..
- 19. With more than one possible media strategy Source: http://en.wikipedia.org/wiki/Spy_Kids http://en.wikipedia.org/wiki/Grindhouse_(film) http://en.wikipedia.org/wiki/Machete_(film) A side character from a movie, then a trailer of a fake movie inside another movie, the the trailer becomes popular and becomes a real movie.
- 20. … and that's not the only case! Source: http://www.flickr.com/photos/catsy/5948099285/in/pool-1206921@N23 http://www.flickr.com/groups/1206921@N23/ http://speckyboy.com/2009/06/12/24-lego-stop-motion-films-mimicking-cool-movies-scenes/ Many different adaptions, photos and videos can be found online. (Solution for the above picture here)
- 21. … and there's an open software for this! Source: http://linuxstopmotion.org/ Linux Stopmotion is a Free Open Source application to create stop-motion animations. It helps you capture and edit the frames of your animation.
- 22. 02. Molding: how to design and mill a mold
- 23. Mold: choose your type A mold can be 1-side or 2-side (or you may not need a mold).So start from these questions: * positive or negative shape? A mold or an object? * which material? Silicon (soft object) or another plastic (hard)? * so..if you want a soft silicon object: no mold * is your object flat on one side or 360*?
- 24. Mold: choose your material Source: http://www.smooth-on.com/ Smooth-On is one of the best manufacturers, but it's not the only one...
- 25. Mold: always read the instructions! Source: http://www.smooth-on.com/ It is very important that you always read the technical bulletin, it will tell you how to work the material, its features and safety information.
- 26. Mold: always read the instructions! Source: http://www.smooth-on.com/ Also check if your material is food safe!
- 27. Mold: choose your material Source: http://silcom.fi/ Silcom is the Finnish distributor of Smooth- On and other brands...
- 28. Source: http://www.flickr.com/photos/aaltofablab/7073792943/in/photostream 1-side mold: relief objects (one flat side) A 1-side mold for an object with one fat side (and a food safe silicon).
- 29. Source: http://academy.cba.mit.edu/2012/students/menichinelli.massimo/index.html 1-side mold: relief objects (one flat side) The fnal fat object (chocolate).
- 30. Source: http://academy.cba.mit.edu/2012/students/menichinelli.massimo/index.html 1-side mold: relief objects (one flat side) The mold designed for milling: it is the negative of what you want to get as a real object!
- 31. Source: http://www.flickr.com/photos/massimo_menichinelli/6766269767/in/photostream 2-sides mold: full 360* objects For objects that are 360* (not just a relief) you will need a two- sides mold, so think about how to split the model in two.
- 32. Source: http://www.flickr.com/photos/massimo_menichinelli/6766270509/in/photostream 2-sides mold: full 360* objects For objects that are 360* (not just a relief) you will need a two- sides mold, so think about how to split the model in two.
- 33. 2-sides mold: full 360* objects For objects that are 360* (not just a relief) you will need a two- sides mold, so think about how to split the model in two.
- 34. 2-sides mold: full 360* objects Add a cone for pouring the fnal plastic into the mold (the mold will be vertical!).
- 35. Source: http://www.bayermaterialsciencenafta.com/checklist/draft_angle.html http://en.wikipedia.org/wiki/Draft_(engineering) Draft angles: it may be hard to remove the part In engineering, draft is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees or mm/mm (in/in).
- 36. 03. Milling and Casting: How to create a mold and use it
- 37. Source: http://www.flickr.com/photos/aaltofablab/6924563776/in/photostream Always, set the Zero: X, Y, Z And write down the X and Y coordinates! Furthermore, don't mill around it, so you can preserve it for future passes.
- 38. Source: http://www.flickr.com/photos/aaltofablab/6924563776/in/photostream Always, use double side tape Use double side tape to stick the modeling wax block to the milling machine, and hot glue if the tape is not strong enough.
- 39. Source: http://www.flickr.com/photos/aaltofablab/6924566732/in/photostream/ Mill it :) You may need to clean the machine to check the progress, but always press the View button before doing it!!!
- 40. Source: http://www.flickr.com/photos/aaltofablab/7070850521/in/photostream Mix and stir the components Most of the time you will have to mix two separate components, always check the instructions, you may need to balance by volume or by weight.
- 41. Source: http://www.flickr.com/photos/narnua/6689110269/in/set-72157628849683783 Use the demoulding spray It will help you when taking the mold away from the wax block.
- 42. Source: http://www.flickr.com/photos/aaltofablab/6924789764/in/photostream Pour the silicon with a steady flow You want to avoid the formation of bubbles inside the mold (or you will have to cast it again), so be careful when pouring the silicon.
- 43. Source: http://www.flickr.com/photos/aaltofablab/7073738569/in/photostream Wait … and repeat! Check the instructions! Sometimes it help for demoulding to leave the stick on the mold … sometimes not!
- 44. Thank you!! Massimo Menichinelli Aalto Media Factory [email protected] @openp2pdesign http://www.slideshare.net/openp2pdesign