Mold Making and Casting: Difference between revisions

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* Desktop Injection Molder
* Desktop Injection Molder
** https://www.youtube.com/watch?v=HoSVPHVESiE
** https://www.youtube.com/watch?v=HoSVPHVESiE
* Resin Printing for Beginners
** https://www.youtube.com/watch?v=UU6tWhV010M


== Materials ==
== Materials ==
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** Tin (Sn) 232C / 450F
** Tin (Sn) 232C / 450F
** Bismuth (Bi) 272C / 521F
** Bismuth (Bi) 272C / 521F
** Bi-Sn tensile strength: 55 MPa, Mild Steel (the cheap stuff): 400-550 MPa, 6061 Aluminum (the cheap stuff): 290 MPa, Tin 220, 3003 aluminum: 186, HDPE plastic 20 - 30, epoxy resin 26 - 85
** Bi-Sn Density: ~8,500 kg/cm3, Mild Steel: 7,850 kg/cm3
** A little denser than steel and a lot weaker than most metal.
** Roughly as strong as epoxy resin (which can be cast in the same molds and is less dense).
* Heat Stable Silicone Mold Release
* Heat Stable Silicone Mold Release
** https://www.amazon.com/dp/B0018NBE8A
** https://www.amazon.com/dp/B0018NBE8A
* Cheaper Tin and Bismuth (free shipping over $150):
** https://www.rotometals.com/tin-cut-wire-pieces-99-9-pure-1-pound-made-in-usa/
== Equipment ==
* Elegoo Mars 1
** 4.7x2.6x6.1 = 120x68x155
= Examples =
== Progress Flag ==
<gallery>
File:Flag cast 01 ingots.jpg
File:Flag cast 02 3d print.jpg
File:Flag cast 03 first mold pour.jpg
File:Flag cast 04 first mold half.jpg
File:Flag cast 05 first pour leftovers.jpg
File:Flag cast 06 kibble.jpg
File:Flag cast 07 mold 01.jpg
File:Flag cast 08 mold 02.jpg
File:Flag cast 09 first cast.jpg
File:Flag cast 10 test casts.jpg
File:Flag cast 11 good cast 01.jpg
File:Flag cast 12 good cast 02.jpg
File:Flag cast 13 flask.jpg
File:Flag cast 14 final.jpg
</gallery>
= Magnet Models =
== Models ==
Shown with example paint schemes.
<gallery>
File:Casting model az state with flag.jpg
File:Casting model flowers 01.jpg
File:Casting model monkey 01.jpg
File:Casting model unicorn 01.jpg
File:Casting model progress flag 02.jpg
</gallery>
== Suggestions ==
* Cactus
* HSL meatball on AZ shape (with rays and blue?)
* Flower
* Mandala
* Dinosaur
* Earth
* Darwin Fish
== Basic Process ==
Mars 1 Bed Size: 68mm x 120mm
# Create a clip art style image in Inkscape.
#* I use layers as my checkpoint stack, so I can recover to a previous checkpoint if needed.
#* Draw outlines only.
#* Use Bezier curves and straight lines.
#* Minimize the number of control handles to get fair curves.
#* File > Document Properties > Page > Custom Size: printer bed size or smaller (portrait or landscape).
#* Set the line width to 0.5mm.
#* Set line ends to rounded.
#* Keep inset regions at least 2mm wide.
#* Clean up everything as much as possible.
#** Check where endpoints meet other curves. Close gaps, pull in dangling ends.
#* Path > Stroke to Path
#* Select 1 path, then all the rest, then Path -> Union
#* Save as SVG
# Import Into Blender
# Set Scene > Units > Length to Millimeters
# Scale the image to smaller than printer bed size (portrait or landscape).
# Convert to Mesh
#* If your design has a lot of lines parallel to the X axis, rotate it 45 degrees before converting. Convert to Mesh has trouble with lines aligned with the X axis.
# Edit Mode > Vertices > Select All > x > Limited Dissolve > 1 degree
# Clean Up Excessive Vertices
#* Loop Select, Remove Critical Vertices, Dissolve by Distance 0.1m or 0.2m
#* Pay Special Attention to Inside Corner Vertices
#* Merge vertices at center or dissolve vertices as needed.
# Loop Select and Create Face
# Inset by 0.5mm
# Clean Up Corners
# Select Inset Face
# Select More
# Unselect Inset Face
# Triangulate Faces
# Select Inset Face
# g > z > 0.7 > - (move face 0.7mm in the negative z direction)

Latest revision as of 00:44, 21 April 2024

Resources

Local Services

Tutorials

Materials

Equipment

  • Elegoo Mars 1
    • 4.7x2.6x6.1 = 120x68x155

Examples

Progress Flag

Magnet Models

Models

Shown with example paint schemes.

Suggestions

  • Cactus
  • HSL meatball on AZ shape (with rays and blue?)
  • Flower
  • Mandala
  • Dinosaur
  • Earth
  • Darwin Fish

Basic Process

Mars 1 Bed Size: 68mm x 120mm

  1. Create a clip art style image in Inkscape.
    • I use layers as my checkpoint stack, so I can recover to a previous checkpoint if needed.
    • Draw outlines only.
    • Use Bezier curves and straight lines.
    • Minimize the number of control handles to get fair curves.
    • File > Document Properties > Page > Custom Size: printer bed size or smaller (portrait or landscape).
    • Set the line width to 0.5mm.
    • Set line ends to rounded.
    • Keep inset regions at least 2mm wide.
    • Clean up everything as much as possible.
      • Check where endpoints meet other curves. Close gaps, pull in dangling ends.
    • Path > Stroke to Path
    • Select 1 path, then all the rest, then Path -> Union
    • Save as SVG
  2. Import Into Blender
  3. Set Scene > Units > Length to Millimeters
  4. Scale the image to smaller than printer bed size (portrait or landscape).
  5. Convert to Mesh
    • If your design has a lot of lines parallel to the X axis, rotate it 45 degrees before converting. Convert to Mesh has trouble with lines aligned with the X axis.
  6. Edit Mode > Vertices > Select All > x > Limited Dissolve > 1 degree
  7. Clean Up Excessive Vertices
    • Loop Select, Remove Critical Vertices, Dissolve by Distance 0.1m or 0.2m
    • Pay Special Attention to Inside Corner Vertices
    • Merge vertices at center or dissolve vertices as needed.
  8. Loop Select and Create Face
  9. Inset by 0.5mm
  10. Clean Up Corners
  11. Select Inset Face
  12. Select More
  13. Unselect Inset Face
  14. Triangulate Faces
  15. Select Inset Face
  16. g > z > 0.7 > - (move face 0.7mm in the negative z direction)
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