Molding and Casting


molding
   types
      injection (sprue, runner, gate, vent, parting line, flashing)
      insert
      vacuum
      blow
      rototional
      flexible, soft
      parts
   vendors
      Smooth-On
      Reynolds Advanced Materials
      Dick Blick
      West Marine
      USG
      Aremco
   materials
      low-temp wax
      machineable wax
      rigid foam
      gesso, hot air
      alginate gel
      urethane rubber, plastic
      silicone
      PDMS (polydimethylsiloxane)
      latex
      thermoplastic, thermoset polymers
      calcium sulfate
         desicant, coagulant, plaster, gypsum, drywall
         DryStone
      Portland cement
         calcium silicate, aluminum/iron oxide, calcium sulfate
         Hydro-Stone
      metal casting
         Cerrotru Zamak aluminum
         clay sand
      glass
      ceramic
      food
   additives
      fibers (tension, compression, composites)
      fillers: density, conductivity, flexibility, color, ...
   processing
      testing
      mixing
      pouring
         starting
         filling
         vent location
      bubbles
         vibration, vacuum, pressure
      curing
         polymerization
         cross-linking
         hydration
         endothermic, exothermic
      demolding
         taper
         release agents
            dilute dish soap, vaseline, talc, ...
         deformation
      storage
      shelf life
   safety
      warnings
      MSDS
      ventilation
      protection
      disposal
   machining
      rough, finish cuts
      cut depth, shank, collet
   software
      ShopBot VCarvePro
      fab modules
         image, mold
         stl, toolpath, mold
         tippy.cad, bottom, top, mold, video

assignment
   design a 3D mold, machine it, and cast parts from it