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mold_cast.html
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<!DOCTYPE html>
<html>
<head>
<title>Molding & Casting - Amanda & EP1000</title>
<link rel="stylesheet" href="style.css"/>
<link rel="preconnect" href="https://fonts.gstatic.com">
<link href="https://fonts.googleapis.com/css2?family=Oxygen+Mono&display=swap" rel="stylesheet">
</head>
<body>
<header>
<h1>Molding & Casting</h1>
</header>
<div class="menu-bar">
<ul>
<li><a href="index.html">Home</a></li>
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<li><a href="mold_cast.html" class="active">Molding & Casting</a></li>
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</div>
<div class="main-text">
<h3>Topics Covered</h3>
<ul style="list-style-type: circle;">
<li><a href="#mold_making">Rigid Foam Mold</a></li>
<li><a href="#silicone-mold">Silicone Mold</a></li>
<li><a href="#epoxy-cast">Resin Cast</a></li>
</ul>
<h3>Introduction</h3>
<p>We are going to be learning how to design and fabricate our own mold and later on use that same mold to cast our model.<br>We would be using <b>rigid foam</b> to create the mold, then using <b>silicone</b> to create the final mold and finally casting with <b>epoxy</b>.</p>
<div id="mold_making">
<h3>Rigid Foam Mold</h3>
<p>While thinking of a design of what I wanted to cast out, I found this 3Dmodel -
<a href="https://www.thingiverse.com/thing:2538251/files">My Customized Rock Climbing Hold</a> by riggsbie on Thingiverse.
<br>I converted the .stl file into a <a href="files/rock_climbing_hold.f3d">.f3d file</a>. I then used this model to create my mold.</p>
<p>I started with the general frame for my mold based on the foam size. In this case was 25mm x 70mm x 70mm. I then included the rock hold model.</p>
<img src="images/mold-frame.PNG" alt="mold-frame">
<img src="images/mold-model.PNG" alt="mold-model">
<div class="embed">
<iframe src="https://ichat1941.autodesk360.com/shares/public/SH35dfcQT936092f0e434f9e1247522cd4fd?mode=embed" width="640" height="480" allowfullscreen="true" webkitallowfullscreen="true" mozallowfullscreen="true" frameborder="0"></iframe>
</div>
<p>I then proceeded to create the g.code for this with Fusion 360's Manufacture Workspace. I used this tool.</p>
<img src="images/edit-tool.PNG" alt="edit-tool">
<p>This is my <a href="files/rock_hold_mold.nc">Rock Hold Mold g-code</a>. This is how my tool-path looked like.</p>
<img src="images/mold-setup-path.PNG" alt="mold-path">
<p>Using the Stepcraft 420, I milled out my rigid foam mold.</p>
<img src="images/mold-mill-details.jpg" alt="mold-mill-details">
<img src="images/mold-mill1.jpg" alt="mold-m1">
<img src="images/mold-mill2.jpg" alt="mold-m2">
<p>I cleaned out the mold, and this is the final product.</p>
<img src="images/mold-milled.jpg" alt="mold-milled">
</div>
<div id="silicone-mold">
<h3>Silicone Mold</h3>
<p>Using the rigid foam mold, I casted a silicon mold with Silicon Rubber RTV-620 which has a ratio of 1:1. First mix the 2 parts togeter qually and evenly, this allows for proper curing if not the silicone would not cure and solidify.</p>
<img src="images/silicone-can.jpeg" alt="silicone-can">
<img src="images/silicone-pour2.jpg" alt="silicone-p1">
<img src="images/silicone-pour.jpeg" alt="silicone-p2">
<img src="images/silicone-poured.jpg" alt="silicone-poured">
<p>As this silicone takes some time to cure, I waited till the next week to start the next process. When I was demolding I found it hard to demold but after abit of pulling here and there I managed to demold the silicone mold.</p>
<img src="images/silicone-cured.jpg" alt="silicone-cured">
</div>
<div id="epoxy-cast">
<h3>Resin Cast</h3>
<p>To create the final model, we would be using Smooth On-Smooth Cast 300. This resin is initially clear but once it cures it turns white. First we prepared the 1:1 ratio of both parts. As this only has a working time of 5-10 mins we need to work fast.
After mixing we would have to immediately pour it into the silicone mold.</p>
<img src="images/epoxy-bottle.jpeg" alt="epoxy-bottle">
<img src="images/epoxy-mix.jpeg" alt="epoxy-mix">
<p>As this resin is fast curing, after 15 mins or so, it is already hardened and ready to demold.</p>
<img src="images/epoxy-cured.jpg" alt="epoxy-cured">
<img src="images/epoxy-demold.jpg" alt="epoxy-demold">
<p>To finish off the rock climbing hold look, I added a socket head screw as well as a nut at the back.</p>
<img src="images/rock-hold.jpg" alt="rock-hold">
</div>
</div>
</body>
<footer>
<p>Copyright © 2022 Amanda Lai</p>
</footer>
</html>