Digital Fabrication Studio 0.3 Molding and Casting

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Digital Fabrication Studio 0.3 Molding and Casting

  1. 1. Digital_Fabrication_Studio.07Molding & Casting –materials,fnishes,processesMassimo Menichinellimassimo.menichinelli@aalto.f@openp2pdesignhttp://www.slideshare.net/openp2pdesign
  2. 2. Today:* Mold* Designing a mold* Casting into a mold
  3. 3. 01.Mold:what can you get out of it?
  4. 4. DIY Blow Molding GunSource: https://vimeo.com/12940879http://www.core77.com/blog/object_culture/george_feredays_personal_blow_molding_gun__16846.aspFrustrated by the limited access to plastic blow-moulding equipment,George Fereday developed his own, outftting a standard mastic gun.
  5. 5. Brickarms: hacking and casting LEGO toysSource: http://www.brickarms.com/BrickArms offers building toy-compatible custom weapons,weapons packs, and custom minifgs.
  6. 6. Brickarms: hacking and casting LEGO toysSource: http://www.flickr.com/photos/enigmabadger/4149563340/in/photostreamA set of pieces.
  7. 7. Brickarms: hacking and casting LEGO toysSource: http://www.flickr.com/photos/enigmabadger/4335841517/in/photostreamThe two-side mold (for injection moulding).
  8. 8. Brickarms: hacking and casting LEGO toysSource: http://www.flickr.com/photos/enigmabadger/4864781771/in/photostreamThe two-side mold (for injection moulding).
  9. 9. Brickarms: hacking and casting LEGO toysSource: http://www.flickr.com/photos/enigmabadger/3643236010/in/photostreamDo you know this guy?(Heres the answer)
  10. 10. Brickarms: hacking and casting LEGO toysSource: http://www.flickr.com/photos/enigmabadger/6174048858/in/photostreamDo you know this guy?(Heres the answer)
  11. 11. BrickForge: hacking and casting LEGO toysSource: http://www.brickforge.com/http://blog.makezine.com/2011/10/12/make-interviews-indie-lego-molder-brickforge/“We consider ourselves intermediaries between thecommunity and the lumbering Danish company.”
  12. 12. BrickForge: hacking and casting LEGO toysSource: http://www.brickforge.com/store/product.php?productid=17777&cat=0&page=(Almost) anything that you cannot fnd in aLEGO store...
  13. 13. BrickForge: hacking and casting LEGO toysSource: http://www.flickr.com/photos/42832748@N05/5680269752/in/photostream(Almost) anything that you cannot fnd in aLEGO store...
  14. 14. Few insights about their processHaving designed the element how do you create the mold?Once the element is designed a mold is created out of aluminum stock using aCNC milling machine. Most of the time we bundle several accessories together onthe same aluminum block. In dealing with such small scale elements we need toinsure 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 andthe 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 machinefeeds the molten ABS into the mold via gates and channels, that then defnes thefnal shape of the object.Source: http://blog.makezine.com/2011/10/12/make-interviews-indie-lego-molder-brickforge/
  15. 15. BrickForge: hacking and casting LEGO toysSource: http://www.brickforge.com/store/product.php?productid=17563&cat=462&page=1=You can be even creative and play with thematerials and their attached meanings...
  16. 16. BrickForge: hacking and casting LEGO toysSource: http://www.brickforge.com/?p=636I mean, really creative....
  17. 17. BrickForge: hacking and casting LEGO toysSource: http://www.flickr.com/photos/42832748@N05/6030380030/in/photostreamI mean, really creative....
  18. 18. … and what can I do with these toys?Source: http://youtu.be/XtkHygcTC8AAnd then the fake trailer is so popular, thatfans make even a Lego version..
  19. 19. With more than one possible media strategySource: 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 insideanother movie, the the trailer becomes popular and becomes a real movie.
  20. 20. … and thats not the only case!Source: http://www.flickr.com/photos/catsy/5948099285/in/pool-1206921@N23http://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. 21. … and theres an open software for this!Source: http://linuxstopmotion.org/Linux Stopmotion is a Free Open Source application to create stop-motionanimations. It helps you capture and edit the frames of your animation.
  22. 22. 02.Molding:how to design and mill a mold
  23. 23. Mold: choose your typeA mold can be 1-side or 2-side (or you may not need amold).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. 24. Mold: choose your materialSource: http://www.smooth-on.com/Smooth-On is one of the best manufacturers,but its not the only one...
  25. 25. Mold: always read the instructions!Source: http://www.smooth-on.com/It is very important that you always read the technical bulletin, it willtell you how to work the material, its features and safety information.
  26. 26. Mold: always read the instructions!Source: http://www.smooth-on.com/Also check if your material is food safe!
  27. 27. Mold: choose your materialSource: http://silcom.fi/Silcom is the Finnish distributor of Smooth-On and other brands...
  28. 28. Source: http://www.flickr.com/photos/aaltofablab/7073792943/in/photostream1-side mold: relief objects (one flat side)A 1-side mold for an object with one fat side(and a food safe silicon).
  29. 29. Source: http://academy.cba.mit.edu/2012/students/menichinelli.massimo/index.html1-side mold: relief objects (one flat side)The fnal fat object (chocolate).
  30. 30. Source: http://academy.cba.mit.edu/2012/students/menichinelli.massimo/index.html1-side mold: relief objects (one flat side)The mold designed for milling: it is the negative ofwhat you want to get as a real object!
  31. 31. Source: http://www.flickr.com/photos/massimo_menichinelli/6766269767/in/photostream2-sides mold: full 360* objectsFor 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. 32. Source: http://www.flickr.com/photos/massimo_menichinelli/6766270509/in/photostream2-sides mold: full 360* objectsFor 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. 33. 2-sides mold: full 360* objectsFor 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. 34. 2-sides mold: full 360* objectsAdd a cone for pouring the fnal plastic intothe mold (the mold will be vertical!).
  35. 35. Source: http://www.bayermaterialsciencenafta.com/checklist/draft_angle.htmlhttp://en.wikipedia.org/wiki/Draft_(engineering)Draft angles: it may be hard to remove the partIn engineering, draft is the amount of taper for molded or cast parts perpendicularto the parting line. It can be measured in degrees or mm/mm (in/in).
  36. 36. 03.Milling and Casting:How to create a mold and use it
  37. 37. Source: http://www.flickr.com/photos/aaltofablab/6924563776/in/photostreamAlways, set the Zero: X, Y, ZAnd write down the X and Y coordinates! Furthermore, dontmill around it, so you can preserve it for future passes.
  38. 38. Source: http://www.flickr.com/photos/aaltofablab/6924563776/in/photostreamAlways, use double side tapeUse double side tape to stick the modeling wax block to themilling machine, and hot glue if the tape is not strong enough.
  39. 39. Source: http://www.flickr.com/photos/aaltofablab/6924566732/in/photostream/Mill it :)You may need to clean the machine to check the progress, butalways press the View button before doing it!!!
  40. 40. Source: http://www.flickr.com/photos/aaltofablab/7070850521/in/photostreamMix and stir the componentsMost of the time you will have to mix two separate components, alwayscheck the instructions, you may need to balance by volume or by weight.
  41. 41. Source: http://www.flickr.com/photos/narnua/6689110269/in/set-72157628849683783Use the demoulding sprayIt will help you when taking the mold away from the wax block.
  42. 42. Source: http://www.flickr.com/photos/aaltofablab/6924789764/in/photostreamPour the silicon with a steady flowYou want to avoid the formation of bubbles inside the mold (or you willhave to cast it again), so be careful when pouring the silicon.
  43. 43. Source: http://www.flickr.com/photos/aaltofablab/7073738569/in/photostreamWait … and repeat!Check the instructions! Sometimes it help for demouldingto leave the stick on the mold … sometimes not!
  44. 44. Thank you!!Massimo MenichinelliAalto Media Factorymassimo.menichinelli@aalto.f@openp2pdesignhttp://www.slideshare.net/openp2pdesign

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