Molding&Casting

Digital Fabrication for Fabacademy
by: Eduardo Chamorro Martín, eduardo.chamorro@iaac.net

Transcript

1. [ Prototyping ] Digital Molding and Casting FabAcademy 2018 - 2019 BARCELONA - SPAIN by: Eduardo Chamorro Martín eduardo.chamorro@iaac.net for
2. Kumar Patel and one of the first CO2 laser cutters 20.000 years B.C - First pottery found , in China area. MOLDING AND CASTING
3. 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
4. DIGITAL FABRICATION
5. DIGITAL FABRICATION
6. MOLDING AND CASTING 3D SHAPE STRATEGY CAST ?
7. 2 OR 3 STEPS PRODUCTION OBJECT MOLD CAST [ CONCEPT ] MOLDING AND CASTING
8. MOLDING AND CASTING
9. 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
10. 3D SHAPE IMAGE SUBSTRACTIVE PROCEDURE CASTED MOLD CASTED PART GEOMETRY POSITIVE MOLD NEGATIVE MOLD RESULT MOLDING AND CASTING
11. 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 ]
12. MOLDING AND CASTING FLEXIBLE APPLICATIONS
13. 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 ]
14. Mold-Cast [ Examples]
15. 3 STEPS CASTS EPS CEU Summer School 2018 MOLDING AND CASTING
16. HARD MATERIAL MOLD Resistant milled mold for casting several negatives MOLDING AND CASTING
17. METAL Soft metal cast on wood mold MOLDING AND CASTING
18. FOOD Chocolate casting with food safe materials MOLDING AND CASTING
19. METAL Soft metal cast on silicone-metal mold MOLDING AND CASTING
20. Injection high pressure injection molding for mass manufacturing MOLDING AND CASTING
21. PLASTER MOLDING AND CASTING
22. LOST MOLD MOLDING AND CASTING
23. Design [ Concerns ]
24. MOLDING AND CASTING DESIGN
25. MOLDING AND CASTING DESIGN Breathing vs pouring conducts
26. TOLERANCES Check the direction of departing, make sure there are ‘space’ MOLDING AND CASTING DESIGN
27. FLEXIBILITY OVERALL SHAPE LOSE DUE TO MATERIAL FLEXIBILITY MOLDING AND CASTING DESIGN
28. STACKING MOLDING AND CASTING DESIGN
29. MOLDING AND CASTING DESIGN MATERIAL - MACHINE LIMITS
30. CENTERING MOLDING AND CASTING DESIGN
31. MOLD-CAST [ Materials ]
32. MOLDING SAFETY CHEMICAL PRODUCTS
33. MSDS Material safety datasheet MOLDING SAFETY
34. Machining [ MOLD ]
35. MSDS Material safety datasheet MOLD MACHINING
36. MODEL 3D modeled geometry with walls MOLD MACHINING
37. MATERIAL Fix the material Safely and setup the XYZ Origin MOLD MACHINING
38. MODEL Calculate height map from 3d MOLD MACHINING
39. ROUGH Height map from 3d model MOLD MACHINING
40. ROUGH Flat endmill offset overlap, high speed MOLD MACHINING
41. ROUGH 2D Flat paths carving the excess material MOLD MACHINING
42. ROUGHING Milling away the big parts MOLD MACHINING
43. ROUGH MOLD ROUGH MOLED WAX RESULT MOLD MACHINING
44. FINISHING Choosing ball nose endmill and toolpaths styles MOLD MACHINING
45. FINISHING Finishig toolpaths MOLD MACHINING
46. MOLD Finish result for casting the flexible negative MOLD MACHINING
47. MOLD MACHINING
48. MOLD MACHINING
49. MOLD MACHINING
50. MOLD MACHINING
51. MOLD MACHINING
52. Machining [ MOLD ]
53. IMAGE 3D SHAPE FROM HEIGHT MAP IMAGE http://cpetry.github.io/NormalMap-Online/ https://tangrams.github.io/heightmapper/ MOLD MACHINING
54. ROUGH Flat endmill offset overlap, high speed MOLD MACHINING
55. FINISH High quality finish cut MOLD MACHINING
56. CASTING [ MOLD ]
57. Bubbles - Make thinnest thread possible and pop bubble if possible - Bang it on the surface for de-airing CASTING MOLD
58. BOX Making a box mold for big scale castings CASTING MOLD
59. CASTING MOLD
60. CASTING MOLD
61. CASTING MOLD
62. CASTING MOLD
63. CASTING MOLD
64. CASTING MOLD
65. CASTING MOLD
66. CASTING MOLD
67. CASTING MOLD
68. CASTING MOLD
69. CASTING MOLD
70. CASTING MOLD
71. CASTING MOLD
72. Machining [ MOLD ]
73. MOLD MACHINING
74. MOLD MACHINING
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87. MOLD MACHINING
88. MOLD MACHINING
89. iaac.net fablabbcn.org Eduardo Chamorro Martín eduardo.chamorro@iaac.net This presentation is a collaborative effort from : Eduardo Chamorro Martin Yongwoo Song the End