This project was created as a part of Carnegie Mellon's DIY Design and Manufacturing course in Spring 2023. The assignment was to create a 2 part silicone mold of an object, and then cast it in resin. The mold could be at most 27 cubic inches while the cast object could be be at most 16 cubic inches. The main point of the project was to get us familiar with a common prototyping method. I decided to mold and cast a rocket shaped chess piece. I went with this object because I find space craft interesting and the shape of it should make it easier to cast.
The first step was to create a positive to cast the mold out of. I choose 3d printing as my positive manufacturing method. I went with this because it would give me the amount of detail necessary while also being easy to do. I printed out a few different designs before settling on the rocket.
Next came the mold designing process. I sketched out a few ways to make my mold before settling one one. With my mold design selected I then when about casting the silicone mod by first using some clay on one side as support and then flipping the 1/2 finished mold over to cast the other side.
With my mold complete I then cast my part out of resin.
I then proceeded to the post processing step to clean up my castings by first removing the added bottom fill area. Covering it in a layer of water based minwax and then applying a grey paint to dull down the shine.
We had 3 criteria for this project.
A 2-3 part mold
At most 27 cubic inch mold
At most 16 cubic inch casted product
I was able to fulfill all 3 of these criteria and was able to check by weighing my mold and casted product at the end.
In conclusion I was able to create a casted product and mold that I was happy with and fit within the materials constraints given.
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