Molding and Casting


molding
   types
      injection (sprue, runner, gate, vent, parting line, flashing)
      insert
      vacuum
      blow
      rototional
      vacuum assist
      flexible, soft
      parts
      registration
   vendors
      Smooth-On
      Reynolds Advanced Materials
      Dick Blick
      West Marine
      USG
      Chockfast
      Aremco
   materials
      low-temp wax
      machineable wax
      rigid foam
         gesso, epoxy, hot air
      wood
      alginate gel
      urethane rubber, plastic, colorants
      clear rubber epoxy
      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 polishing
         Cerrotru
         aluminum clay sand glass
      ceramic
      food
   additives
      fibers (tension, compression, composites)
      fillers: density, conductivity, flexibility, ...
   processing
      workspace
      testing
      mixing
         weight
         volume
         consistency
         striations
      pouring
         starting
         filling
         vent location
      bubbles
         stirring, pouring, vibrating, painting, vacuum, pressure, time
      curing
         polymerization
         cross-linking
         hydration
         endothermic
         exothermic
      demolding
         draft angle
         release agents
            dilute dish soap, vaseline, talc, ...
         deformation
      storage
      shelf life
   safety
      warnings
      SDS
      ventilation
      protection
      disposal
   machining
      surface finish
      rough, finish, stepover
      tool types
         flat end
         ball end
         extra long, long neck, tapered
         micro
      cut depth, shank, collet, collision, slope
   software
      ShopBot VCarvePro
      Fusion 360 Moldflow
      Solidworks Plastics
      fab modules
         image, mold
         stl, toolpath, mold
         tippy.cad, bottom, top, mold, video
      (mods)

assignment
   group assignment:
      review the safety data sheets for each of your molding and casting materials,
         then make and compare test casts with each of them
   individual assignment:
      design a mold around the stock and tooling that you'll be using,
         mill it (rough cut + (at least) three-axis finish cut),
         and use it to cast parts