Showing posts with label mold. Show all posts
Showing posts with label mold. Show all posts

How crazy are the Finns?

Well ... besides crushing various thing in a hydraulic press they also use LARGE 3d printers at Prenta to make molds for pykrete stuff. Pykrete ammunition to be more specific.




And then they use that ammo in a BIG air cannon:




I like Finland!


Prenta homepage (largest 3d printing machines in Scandinavia):

http://www.prenta.fi/en/

If you don't know what pykrete is:

https://en.wikipedia.org/wiki/Pykrete


DIY Silicone Nozzle Cover

One way to protect your nozzle from getting dirty is to wrap it in a cover, sock, sleeve or boot and prevent all the hot nasty stuff sticking to it. E3D released their silicone sock for Vulcano nozzles but someone found a way to make a DIY version.

Ubermeisters used 3d printed model of the nozzle and made a mold around it and than used some high temperature silicone mixture to produce the final cover. All steps are photographed in detail.



















Here are the files and the instructions:

https://www.youmagine.com/designs/e3d-volcano-silicone-casting-mold

Build log gallery:

http://imgur.com/gallery/vHDmL

And here is the E3D sock:

http://e3d-online.com/Socks-Launch

Reinforcing thin concrete objects with 3d printed mesh

For some DIY projects you need thin concrete or cement walls. They are prone to brake under tension or fall impact.
Instructables user "ucn" from Singapore wanted to make strong thing concrete molded business cards and successfully reinforced them with 3d printed mesh frame. It looks that this technique works great and could be applied to other concrete projects where you need internal reinforcement structure.




Here is a detailed buold guide with prototypes that led to final sucess and strenght testing:

http://www.instructables.com/id/3D-Printed-Reinforced-Concrete-Business-Cards/?ALLSTEPS

How to make big silicone molds from 3D printed objects

Volum3 from Romania made a tutorial on how to make large molds with several 3D printed parts acrylic plaster and silicone that can be used to cast relatively big objects from polyurethane foam.




Instructables page:

http://www.instructables.com/id/How-to-Make-a-Cheap-Silicone-Mold-of-a-3D-Printed-/




Industrial Size 3D Printed Wind Blade Mold

How big can you go with high-end industrial 3D printers? VERY big! Here is a wind blade mold for research in wind power.
The mold for making the blades is being printed using the Big Area Additive Manufacturing (BAAM) machine at the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory. BAAM is 500 to 1,000 times faster and capable of printing polymer components 10 times larger than today’s industrial additive manufacturing machines. Since the molds will be used to create research blades measuring 13 meters (42 feet) in length, BAAM provides the necessary scale and foundation for this ground-breaking advancement in blade research and manufacturing.


Source:

http://energy.gov/eere/amo/articles/global-wind-day-2016-amo-s-role-applying-3d-printing-wind-blade-mold-manufacturing

HydroSpan 100 Water Enlarging Polymer

I was searching for water hardened polymers and I accidentally found this: the HydroSpan 100 Enlarging Polymer. It is a polymer that grows in water by absorbing it. It grows BIG!

Here is the HydroSpan description:
HydroSpan 100 is a unique two component, Flexible, 100% solids (contains no V.O.C.), polyurethane elastomeric compound. HydroSpan 100, when fully cured provides a simple method for expanding three dimensionally molded parts. Expanding parts is done by simply molding the part with HydroSpan 100 to from a rubber master. After curing 24 hours at room temperature the molded HydroSpan 100 part is soaked in room temperature water and allowed to expand. Full expansion is 161% larger than the original part. Full expansion of parts can be achieved in 5 to 14 days depending on cross section thickness of the part. Thicker cross sections take longer while thinner cross sections require less time.

The video of polymer being used:




So how is this connected to 3d printing? Imagine if we had similar material for 3d printed objects? You print them out, leave them in water and they grow several times. Hopefully someone will develop this concept :-) You have seen it mentioned here first :-) !


Product homepage:

http://www.industrialpolymers.com/hydrospan/hydrospan-100



Apple and Autodesk Patent Color 3D Printing (Apple patents liquid metal casting also)

OMG NOOOOO ... Apple files a patent for a 3d printer that prints colored objects with color being applied by separate nozzle. Maybe it's a tipe of defensive patenting or some corporate IP strategy. I hope they develop it and make it cool, but after Apple Pen fiasco I'm not getting my hopes up ...















Patent page:

LINK

PS: I am really not an Apple fan ...

Update (21.2.2016.)

Autodesk has patented color 3d printing also. Maybe it is the beginning of color patent wars.

http://3dprint.com/74984/autodesk-patent-multi-color/

Update (19.3.2016.):

Apple has filed for a new patent connected to 3d printing and molding technologies:
Apple’s patent application covers a method for 3D printing investment molds to be filled with molten amorphous alloy. These alloys are configured to form a bulk metallic glass (BMG) on cooling. BMGs, (also known as Bulk Amporhous Alloys) are a new class of metallic alloys that are extremely strong, with superior elastic strain limits and resistance under shock impact. They are therefore ideal for the manufacturing of electronic device housings and cases.
Here is a patent page: LINK



Looks like Apple is going into transformable and liquid metals!!! Remember Terminator ...

Source and ore info:

http://www.3ders.org/articles/20160310-apple-files-patent-application-for-3d-printing-investment-molds.html

How to make a DIY injection molding machine from a drill press

If you want to make mass produced parts you will reach a limits of your 3d printed very quickly both technical and economical ones. For any serious mass production of plastic parts you must use injection molding which can be expensive in the beginning since the initial mold is costly but the parts are cheap afterwards.

Is there a middle ground? A device you can build yourself?
There is a possibility to make a DIY home workshop injection molding machine from a hacked press drill with Gingery attachment and a CNC milled metal mold.
You can use various types of thermoplastics like: PETE, HDPE, PVC, LDPE, PP, PS and ABS.

Scorch from Scorchworks documented his experience with it.

Here is a construction video of Gingery injection molding tool for a simple drill press:




Here is a demonstration of injection molding plastic parts into CNC milled molds:



For more info on his project see:

http://www.scorchworks.com/Injection_molding/injection_molding.html


For a simple DIY drill press injection molding apparatus you can check out this PDF guide:

http://rick.sparber.org/Articles/gpi.pdf


The setup:



Injection molded objects and the mold:



3D Printing food by FabLab Maastricht

Thomas Sanladerer made this interesting video on 3d Printshow Berlin 2015 about 3d printing food items on a machine developed by FabLab Maastricht. They also involve local chefs and create food silicone molds for food pieces.




Here is the link to the FabLab page:

http://www.fablabmaastricht.nl/en/research-3dfoodprinting

Here is a video with an interview:



Using home microwave for lost PLA 3d printed aluminum parts

Lost PLA is method used to produce cement molds for metal casting and it is used mostly with molten aluminum. Desired object is 3d printed in PLA, cast is made around it and the PLA is melted away. The mold is then used for metal casting. Entire process is usually done with a propane gas powered kiln or smelter, and this project used home microwave oven.

The process is simple but you will need to take safety seriously. Object 3d printed in PLA is coated with susceptor that transforms microwaves into heat. Susceptor is made from mixture of silicon carbide, sugar, water, and alcohol. The part is then placed in a mold made of plaster of paris with perlite and heated in an unmodified household microwave to burn out the PLA.
A second microwave with a top emitter is used to melt aluminum, which is then poured into the prepared mold. When the metal cools down, the mold is broken to take out the metal part for post-processing



























From project description:
Our system uses consumer microwave units to perform burn-out of PLA from molds, and a second microwave to liquify aluminium, to be poured into the mold. 3d printer inspired mechanics will move the aluminium from the microwave, into the target mold under human control across the network, so that there is no risk to the person operating the machine.
What is working and what we're working towards:
What works now is that we are able to successfully melt aluminum inside a microwave and supply our molds to get fine quality crafted aluminium parts.
The vision is to automate the process and build machines so that the system can be remotely run by a human being safely from their terminal.
Automation will be as simple as two to three machines powered by arduino with minimum axes.

One machine will be a forklift to pickup the item and deposit it safely onto a pair of fire bricks. One is a crane to pickup the top from the kiln, and one is a combination of forklift and a x,y table. This will pickup the cup, place over target, and pour through a heated steel funnel into the mold.
Ideally, we see an operator walking to the machine, starting the microwave on the mold & aluminium. When notified the machine is done, the operator can use gloves to pickup and bury the mold in sand, then walk back to their workstation, and pour the aluminum remotely. This will reduce the risk of injury to an operator to near 0, and not require any dangerous gasses to perform the melt.
All of the software will be released under the GNU GPL V3 as the project advances, with the hardware designs released under the TAPR OHL.

Detailed project page and build log on hackaday.io:

http://hackaday.io/project/2434-microwave-aluminium-printing

Project homepage:

http://fosscar.faikvm.com/trac/wiki/LostPLA


UPDATE:

Here is very detailed video presentation by Julia Longtin on Chaos Computer Club 31th Chaos Communication Congress. It is a great how-to guide on casting high quality 6040 aluminum pieces using a 3D printer and commercially available consumer microwaves



Here is a more detailed guide on how to make and use microwave oven DIY smelter for silver or tin solder:

http://www.instructables.com/id/microwave-smelter/?ALLSTEPS





Here is a different approach to melting aluminum in a microwave oven:



Cost reduction and time saving blow mold production with 3d printing





Blow molding is process mostly used for manufacturing of various containers such as bottles. With the help of 3d printers the time of mold production is reduced by 90% and cost are cut by 94%.

Blow molding is a manufacturing process used to produce hollow plastic parts, such as bottles and other containers. Blow mold design and the specification of process parameters require skill and precision. A small change in the pinch--off or vent design, die temperature or blow pressure can dramatically affect the molding results.

Prototyping enables designers to validate these parameters and accelerate design approval. But up till now, high costs and long lead times have deterred blow mold prototyping.

Additive manufacturing, or 3D printing, makes prototyping a viable option. In this brief video you will learn how to produce cost-effective blow molds using PolyJet-based 3D printing from Stratasys.

3d printed vs. cnc machined aluminum blow molds
















Source: http://blog.stratasys.com/2014/06/30/3d-printed-blow-molds-plasel

More bronze objects made with lost PLA casting method

More lost PLA casting technique pictures. Seems like  people are using it more and more to make unique metal pieces. Results in bronze seem to be very good.




I found it on Reddit published by use milkshakeconspiracy

http://www.reddit.com/r/3Dprinting/comments/27m4mn/random_lostpla_castings_i_have_been_working_on/

his previous work with build log can be found here:

http://diy3dprinting.blogspot.com/2014/04/photo-buildlog-on-how-to-cast-metal.html



RotoMAAK bridging the gap between 3d printing and fast manufacturing





RotoMAAK is DIY rotational casting machine that can produce casted resin models fast. Molds can be made from 3d printed objects, so you can produce small series very fast.

From Kickstarter description:
The RotoMAAK

Rotational Casting, also known as Rotocasting or Hollow Casting, is a molding process for creating many kinds of items, mostly hollow in form and typically made of plastic. The RotoMAAK rotocaster was born out of the desire to have a process by which Makers could scale up production of parts using rotational casting technology when 3D printing a small production run becomes cost and time prohibitive.
HOW DOES IT WORK?
The RotoMAAK rotational caster consists of a hollow mold and a rotational device that spins the mold in a uniform motion. The hollow mold is filled with a charge or shot weight of air cure resin. It is then inserted into the RotoMAAK where it is slowly rotated (usually around two perpendicular axes) causing the liquid resin to uniformly disperse and stick to the walls of the mold where it slowly cures over time into the shape of the part. In order to maintain an even thickness throughout the part, the mold continues to rotate at all times during casting phase and curing phase. The continuous rotation of the mold also avoids sagging or and part deformation.
The rotocasting process was applied to plastics in the 1940's, but in its early years was rarely used due to a slow process and restriction to a small number of plastics. Over the past two decades, improvements in process control and developments with air cure resin and plastic powders have resulted in a significant increase in its usage for part production.
OUR INNOVATION:
The RotoMAAK rotational casting machine allows the hobbyist to experiment with different casting materials and mold creation for production scale-up of parts to meet customer needs. With the popularity of DIY 3D printing, you now have the ability to create a 3D object in a relatively short amount of time compared to the traditional prototyping or one off manufacturing processes. 3D Printing allows you to create one part faster than traditional processes, but not reproduce it as quickly as mass manufacturing technologies. With rotational casting, you have more options to reproduce many identical parts from a successful print. Additionally it is not limited to 3D printed molds (NO 3D Printer required!), you can create a mold from almost any part and in turn reproduce multiple replicas of that item.
ADVANTAGES
One of the major advantages of rotocasting a hollow part is the savings in materials and weight. If a part's function does not require it to be solid, why cast it solid and waste materials? Instead of using pounds of material to cast a solid piece, you can cast it hollow with ounces of resin, which in turn yields a big cost savings in time and material.
The RotoMAAK also controls the rotation of the mold to ensure a uniform wall thickness that rotating a mold by hand cannot achieve. Some air cure resins,especially the clear varieties, have a cure time of several hours instead of 6-10 minutes. Evenly rotating a mold for hours would prove to be impossible by hand, and a rotational machine like this will allow you to rotational cast clear bottles, glasses, etc. for amazing special effects.
MARKET
First we were looking at ways to increase the speed of reproducing 3D printed parts, either by using a mold that was 3D printed and cast directly from that, or by 3D printing your part and creating a silicon mold from that. However, after talking to many people at Maker Faires, other Makers and hobbyists in the community, and others with manufacturing experience and creative tendencies, we have identified even more niches and applications for this technology than we first envisioned. Many different people: doll makers, artists, model makers, action figure enthusiasts, can go from clay original to silicon mold to producing and selling limited edition reproductions. Candy makers can make custom and personalized hollow chocolate figures, even people making R2-D2 replicas with hollow parts that have been cost prohibitive to have machined. Custom bike builders can even rotational cast specialty/themed turn signal lenses.
The possibilities are endless! Rotational molding parts with the RotoMAAK can save you time and money, and is a bridge between one off part production and the cost of injection molding.

Rotational caster can be your printers best friend. I think we will se more of those machines in the future, and Rotomaak will be open sourced. Kudos for that! Sharing is caring!




They just had finished successful Kickstarter campaign with 211 backers that pledged $52,800 of $17,000 goal. Great work!

https://www.kickstarter.com/projects/rotomaak/rotomaak-desktop-rotational-casting-machine

RotoMaak homepage:

http://rotomaak.com/

First post about RotoMaak:

http://diy3dprinting.blogspot.com/2013/10/rotomaak-diy-spin-casting-machine.html


Example of figurines made by rotocasting on RotoMAAK with different resins



Off topic: Can City DIY mobile foundry for aluminum recycling




If DIY molten aluminum printing gets real, recycling in poor areas will definitely change as they will have cheap but powerful manufacturing tool.



























Source: http://solidsmack.com/fabrication/can-city-fabricating-furniture-from-melted-aluminum-cans-on-the-streets-of-sao-paulo/

Improving production process, reducing cost and shortening time in high-tech production by using 3d printers in Seuffer company

This video shows how German midsize high-tech company is using 3d printing to optimize it's production process, cut costs drastically and reduce time needed for component manufacturing.



RotoMAAK - DIY spin casting machine

Desktop spin casting machine would enable you to make series of objects with rapid molding process. This could develop into very interesting sector of machines and products.




Co-Founder of TeMAAK and Inventor of the RotoMAAK, Mark VanDiepenbos presents the RotoMAAK desktop rotational molding machine and demonstrates its use.
The RotoMAAK evenly distributes 2 part epoxies, as well as other rotational mold materials, to make parts out of 3d printed molds, silicon molds, or other types of molds in as little as 5 to 10 minutes. More details and specs coming soon, including the date for the Kickstarter campaign. Sign up on their website www.rotomaak.com to receive email notifications about its development and Kickstarter Launch.
Mark VanDiepenbos is a part of Makerspace Goshen, the same group that John Oly and Steve Wygant of www.seemecnc.com (Rostock Max and Orion 3D printers) are a part of.

If you are not sure what spin casting is (like I was) here is wikipedia page on it: http://en.wikipedia.org/wiki/Spin_casting

Here is a link to another DIY spin casting centrifuge that illustrates the process:

http://www.myheap.com/chapter-2-tools/a-spin-casting-centrifuge.html

Update (17.3.2014.):

Here is Mark on Midwest RepRap Festival showing 3d printed resin molds.





Update (23.4.2014.):

RotoMAAK just finished its Kickstarter campaign with excellent results:

http://diy3dprinting.blogspot.com/2014/04/rotomaak-bridging-gap-between-3d.html


More details on the Othermill, desktop CNC machine that is perfect companion to a 3d printer

Tested.com gives us the tour of Otherfab and presentation of Othermill, tabletop precision mill.  Othermill team member talks about design for milling and connection with 3d printing.  Primary job of the Othermill is PCb milling, but it can also mill aluminum and make molds from machinable wax.
Very cool device, perfect in synergy with a 3d printer.
There is a trend of hybrid machines with both 3d printing and milling options in one machine, but designated machines can probably do the specific job they were designed for much better.





First post about Othermill: http://diy3dprinting.blogspot.com/2013/05/othermill-desktop-precision-mill.html


Company page: http://otherfab.com/, www.othermachine.co
Direct Othermill product page: http://www.othermachine.co/products/





Othermill frame 






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