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(For the purposes of Midnight Sun, we use molds (styrofoam, MDF, or others) to create the aerobody using materials such as carbon fiber.)
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Tolerances: This is the allowable margin of error or variations that is acceptable for reproductions of the original part. This would impact assemblies of objects, enclosures, open parts, and others.
Regardless of what type of mold and process is used, the reproduced part must be able to be removed from the mold. The more complicated the design is, the more difficult it gets to remove, thus designs must account for these properties.
Draft angles, the angle of taper away from the perpendicular (degrees), that are added to SolidWorks models to aid the removal of the object. More drafts are added depending on the complexity and textures in the design.
Fillets are rounded edges included in designs to facilitate the smooth flow of the cast material into the mold. Otherwise, issues such as air bubbles and will add stress to the part.
Vents are built in (depending on the casting process used) to allow for air to be better displaced by the casting material.
Creating Molds in SolidWorks
(Finally here, eh?)
Let's start with some simple models in SolidWorks to create molds out of. The method we are using is to create the negative space around the part.