Molding&Casting - Speaker Deck

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[ Prototyping ] Digital Molding and Casting FabAcademy 2018 - 2019 BARCELONA - SPAIN by: Eduardo Chamorro Martín [email protected] for

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Kumar Patel and one of the first CO2 laser cutters 20.000 years B.C - First pottery found , in China area. MOLDING AND CASTING

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Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process [ Several Steps Procedure to produce Durable Parts ] MOLDING AND CASTING

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DIGITAL FABRICATION

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DIGITAL FABRICATION

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MOLDING AND CASTING 3D SHAPE STRATEGY CAST ?

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2 OR 3 STEPS PRODUCTION OBJECT MOLD CAST [ CONCEPT ] MOLDING AND CASTING

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MOLDING AND CASTING

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ONE SIDE MOLD TWO SIDE MOLDS To produce diﬀerent pieces we need to ﬁrst think on how we are going to design our part, as it changes completely the manufactoring procedure. Some objects , like a badge could be produced used one side mold where we only reproduce the design in one of the sides. In case we want to reproduce our piece completely tridimensional we will need a two side mold and in case of higher complexities maybe 3-4-5... sides molds MOLDING AND CASTING

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3D SHAPE IMAGE SUBSTRACTIVE PROCEDURE CASTED MOLD CASTED PART GEOMETRY POSITIVE MOLD NEGATIVE MOLD RESULT MOLDING AND CASTING

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MOLDING AND CASTING 1. Prototyping 2. Dental CAD/CAM 3. Jewelry Manufacturing 4. Low precision wax casting 5. Mold making 6. Automation appliances(gear, turbine etc.) 7. High resistant parts [ Tipical Applications ]

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MOLDING AND CASTING FLEXIBLE APPLICATIONS

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MOLDING AND CASTING 1. Machinable wax 2. Low-temp wax 3. Rigid foam 4. Alginate gel 5. Urethane rubber,plastics 6. Silicones 7.Latex 8.Plaster 9.Cements 10.DryStones 11.Metal 12.Glass 13.Food 14.Resins [ Materials ]

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Mold-Cast [ Examples]

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3 STEPS CASTS EPS CEU Summer School 2018 MOLDING AND CASTING

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HARD MATERIAL MOLD Resistant milled mold for casting several negatives MOLDING AND CASTING

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METAL Soft metal cast on wood mold MOLDING AND CASTING

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FOOD Chocolate casting with food safe materials MOLDING AND CASTING

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METAL Soft metal cast on silicone-metal mold MOLDING AND CASTING

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Injection high pressure injection molding for mass manufacturing MOLDING AND CASTING

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PLASTER MOLDING AND CASTING

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LOST MOLD MOLDING AND CASTING

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Design [ Concerns ]

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MOLDING AND CASTING DESIGN

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MOLDING AND CASTING DESIGN Breathing vs pouring conducts

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TOLERANCES Check the direction of departing, make sure there are ‘space’ MOLDING AND CASTING DESIGN

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FLEXIBILITY OVERALL SHAPE LOSE DUE TO MATERIAL FLEXIBILITY MOLDING AND CASTING DESIGN

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STACKING MOLDING AND CASTING DESIGN

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MOLDING AND CASTING DESIGN MATERIAL - MACHINE LIMITS

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CENTERING MOLDING AND CASTING DESIGN

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MOLD-CAST [ Materials ]

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MOLDING SAFETY CHEMICAL PRODUCTS

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MSDS Material safety datasheet MOLDING SAFETY

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Machining [ MOLD ]

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MSDS Material safety datasheet MOLD MACHINING

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MODEL 3D modeled geometry with walls MOLD MACHINING

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MATERIAL Fix the material Safely and setup the XYZ Origin MOLD MACHINING

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MODEL Calculate height map from 3d MOLD MACHINING

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ROUGH Height map from 3d model MOLD MACHINING

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ROUGH Flat endmill oﬀset overlap, high speed MOLD MACHINING

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ROUGH 2D Flat paths carving the excess material MOLD MACHINING

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ROUGHING Milling away the big parts MOLD MACHINING

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ROUGH MOLD ROUGH MOLED WAX RESULT MOLD MACHINING

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FINISHING Choosing ball nose endmill and toolpaths styles MOLD MACHINING

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FINISHING Finishig toolpaths MOLD MACHINING

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MOLD Finish result for casting the ﬂexible negative MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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Machining [ MOLD ]

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IMAGE 3D SHAPE FROM HEIGHT MAP IMAGE http://cpetry.github.io/NormalMap-Online/ https://tangrams.github.io/heightmapper/ MOLD MACHINING

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ROUGH Flat endmill oﬀset overlap, high speed MOLD MACHINING

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FINISH High quality ﬁnish cut MOLD MACHINING

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CASTING [ MOLD ]

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Bubbles - Make thinnest thread possible and pop bubble if possible - Bang it on the surface for de-airing CASTING MOLD

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BOX Making a box mold for big scale castings CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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CASTING MOLD

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Machining [ MOLD ]

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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MOLD MACHINING

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iaac.net fablabbcn.org Eduardo Chamorro Martín [email protected] This presentation is a collaborative effort from : Eduardo Chamorro Martin Yongwoo Song the End