Roland in Fusion - RML

See Lindas FabAcademy Assignment

Group assignment:

Review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them

Individual assignment:

Design a 3D mold around the stock and tooling that you'll be using, machine it, and use it to cast parts

Learn about 3D machining

Molding & casting

Surface finish

Easy reproduction

Insert molding - put something in to it

• 1/32 endmill

Molded in to parts, the one mold, slides into the other

See Bas page

Vacum former

Multiple part molds

Decompose design into a set of perspectives

Materials

FlexWax - https://www.dickblick.com/products/amaco-flexwax-moldmaking-material/

create for mold repair

Can cast from an object

Maschineable Wax - http://www.machinablewax.com/

Rigid foam

     gesso, epoxy, hot air

  alginate gel

  urethane rubber, plastic

  clear rubber epoxy

  silicone

  PDMS \(polydimethylsiloxane\)

Latex - takes week to dry

Thermoplastic, thermoset polymers

  calcium sulfate

     desicant, coagulant, plaster, gypsum, drywall

Drystone - https://plaster.com/product/usg-drystone/

Lav visositet, hårde dele, let at arbejde med.

Portland cement

     calcium silicate, aluminum/iron oxide, calcium sulfate

     Hydro-Stone - https://plaster.com/product/usg-hydrostone/

Metal casting polishing

Mold should be dusted with calc powder.

Cerrotru - https://www.rotometals.com/roto281f-low-melt-fusible-bismuth-based-alloy-ingot/

Feel like metal, low temp melt

Aluminum clay sand glass

Requires high temp

Ceramic

Food-safe

The hole production should be food safe.

https://www.smooth-on.com/product-line/sorta-clear/

https://www.smooth-on.com/products/oomoo-30/

Hæld en tynd ståle og lad det flyde.

Hul, hvor lugt kan slippe ud

Hold formen skæv, mens der hældes,

Pas på luftbobler:

Stir slowly to avoid bubles. Sheering not scooping

Shake - agitate it -

Paint material in a thin layer

Vakum beholder - der suger luften ud

Proces:

• Testing
• Mixing - weight, volume, consistency
• Pouring - starting, filling, vent location
• Bubbles - vibration, vacuum, pressure
• Curing - exotermisk - raises heat, Different Pot life and cure time
• Demolding, taper
  • Easier to get out
  • Flexible mold easier to get out
  • Urethane in urethane will stick, and maybe require release agents
• Storage, temperature and shelf life

Safety

• Warnings
• Read SDS before use
  • OOMOO - https://www.smooth-on.com/msds/files/BD_DS_Eco_Equ_EZB_EZS_Psy_MS_OOMOO_Reb_ST_SS_Soma_Sol_Sorta.pdf
  • Hyperstone
• Ventilation
  • Urethane
• Protection
  • Dirty clothes
• Disposal

Machining:

Rough - quick for chip removal

Finish cuts - academy.cba.mit.edu/classes/computer_machining/cuts.png

Tool types

• flat end
• Carbide Endmills: http://www.carbidedepot.com/Endmills-Carbide-C6.aspx

• Ball end

• Extra long, long neck

• Micro

• Does the flute match the shank?

Design a mold around the tool.

Flat End vs Ball

Flat End for roughing (material removal) and for flat bottoms

Ball for smooth surface sloping surfaces.

Cut depth: check for potential collision of shank, collet and spindlehead

Use slopes to avoid touching of the shank.

One mold, that fits in the other.

OOMOO

Urethane

Evt. metal'

Adjusted cutting proces:

Half feedrate

Reduction from 14000 to 8000 RPM.