Step-by-step guide
Definitions
Let's start with a few definitions.
A mold is a 3D negative part of an object with the goal of capturing all geometric features of the original part.
Moldmaking is the process of creating the 3D negative space to allow for creating reproductions that are identical to the original part.
A cast is the reproduction of the original part. Casts can be made from different materials depending on the requirements.
Casting is the process of reproducing the original part. The process consists of filling the mold cavity (or cavities) with materials that hardens (typically polymers - more on materials in Mold Materials, Mold Processes) and then removed from the mold once cured. Depending on the mold materials, casting can occur multiple times within the same mold.
The process of curing is the hardening of polymer materials.
Casting Production Cycle:
- Preparation of Material
- Filling the Cavity
- Curing Processing time
- Cooling/solidifying of the cast
- Ejection from mold
(For the purposes of Midnight Sun, we use molds to create the aerobody using materials such as carbon fiber. )
Design Considerations
In general, considerations must be made for mold design in any application, especially in mass manufacturing.
Repeatability: The mold should be able to be used multiple times, each producing a replica of the original part.
Efficiency: uses the available technology to minimize waste, optimize production, and reduce time.
Quality: These are the standards set by an industry or policies. In any case, quality is the ratio of value to cost. Does the product create enough value to the user for its cost?
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.