Moulding and Casting

Updated for the latest Fab Academy * evaluation standards!

• Group assignment

  • Review the safety data sheets for each of your molding and casting materials
  • Make and compare test casts with each of them

• Individual assignment

  • Design a 3D mould 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.

Learning outcomes

• Design appropriate objects within the limitations of 3 axis machining
• Demonstrate workflows used in mould design, construction and casting

Have you?

• Included ‘hero shot’ of the mould and the final object
• Linked to the group assignment page where you reviewed the safety data sheets for each of your molding and casting materials, then made and compared test casts with each of them
• Documented how you designed your 3D mould and created your rough and finish toolpaths for machining, including machine settings
• Shown how you made your mould and cast the parts
• Described problems and how you fixed them
• Included your design files

FAQ

Should I mill a mould for the group assignment?

Answer: No, group assignment is for you to get familiar with the materials and the processes.

Should I read the MSDS and TDS this week?

Answer: Yes, always. Document the main points.

I want to only make a wax mould, and cast something in it. Is that acceptable?

Answer: Only after you learn and go through the 3 step process. To break the rules, you have to master the rules.

What does 3-axis milling mean?

Answer: You should have smooth tilted or curved surfaces instead of "steps" towards axis Z.

Can I 3D print the mold? Can I do a lasercut?

Answer: No, for this assignment you must mill the mould using a CNC milling machine. After fulfilling the requirements, please go ahead and experiment other techniques for fabricating moulds.

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