Education in plastics manufacturing: Aluminum mold making and injection molding

Plastics are ubiquitous in the modern world with both positive and negative consequences. Students will benefit from understanding how plastics are manufactured. They will be more aware of the material and have a better appreciation for the need to recycle. Injection molding is one of the primary plastics manufacturing methods and hobby scale injection molding machines can be used to educate students about plastics and polymers. Furthermore, it is possible to create custom injection molds from aluminum using similar hobby scale tools. In this article, experiences introducing injection molding in the classroom and experiences with mold making as a senior design project are presented. Suggestions and procedures for using the injection molding machine and for creating custom aluminum molds are covered.

Sand Casting Implementation of Two-Dimensional Digital Code Direct-Part-Marking Using Additively Manufactured Tags

Statistical quality control is used in foundries to identify special cause defects and root causes by correlating process input variations with casting defects. A difficulty exists in associating process data collected with individual cast parts as the parts are processed through the foundry and then out into the supply chain. Typically, alphanumeric labels for marking castings and manual identification of the castings with route-paper based tracing approaches have been used. Such manual-based systems make root cause analysis of quality defect issues tedious. This study presents the development of a semi-automated approach using 3D printed sand mold inserts shaped as 2D matrix codes which thereby permit directly cast identification code into the parts. This enables automated part tracking at the very beginning of the casting process including mold making. Automated scan based tracking of parts through a foundry and subsequent supply chain allows for statistical process data collected to also be associated with each part processed with unique identification, building upon the part history and pedigree.

Thermal Properties of 3D-Printed Sand Molds

Specific heat capacity (Cp), density (ρ), and thermal conductivity (λ) of phenolic-bonded 3D-printed sand (3DPS) molds have been determined in the temperature range of 20–1400 °C using differential scanning calorimeter (DSC), dilatometer, and hot wire method. The results have been used to simulate the thermal gradient in a sand mold during casting aluminum using a commercial simulation software. The simulated results have been compared with laboratory-measured results and simulated results using the software’s database for conventional mold making. Our results show that available database for sand thermal properties cannot explain the thermal gradient in 3DPS molds and this manufacturing process affects the thermal properties of the mold compared to traditional mold making. It is necessary to collect data for a variety of 3D-printed sand molds to ensure accurate modeling simulation in the foundry industry.

PLASTER - POLYESTER CASTING TECHNIQUES IN THE ART OF SCULPTURE

Sculpture art forms an integrity within itself in mass and volumetric sense in the period from the first age to the present in the classical sense. Likewise, the art of sculpture made progress by developing itself further with concepts such as mass, volume, emptiness, fullness, light and shadow, which were revealed in the medieval and baroque period. Especially the separation of the sculpture, which was created with classical materials, with different phenomena with the formation process (clay, mud, marble, wood, bronze, etc.) began to express itself as a separate definition with casting processes as well as molding with materials. In this study, mold making processes, which are indispensable of sculpture art, will be examined by using two different casting techniques from sculptures that have been molded. In this context, it is observed that gypsum mold and polyester mold technologies continue to be used today with the developments and changes that they have undergone from the past to the present. To summarize, within the scope of this study, detailed processes related to casting the work whose mold was taken over classical sculpture technology were explained. Keywords: Sculpture, mold, casting, plaster, polyester

Leveraging the Advantages of Additive Manufacturing to Produce Advanced Hybrid Composite Structures for Marine Energy Systems

Many marine energy systems designers and developers are beginning to implement composite materials into the load-bearing structures of their devices, but traditional mold-making costs for composite prototyping are disproportionately high and lead times can be long. Furthermore, established molding techniques for marine energy structures generally require many manufacturing steps, such as secondary bonding and tooling. This research explores the possibilities of additively manufactured internal composite molds and how they can be used to reduce costs and lead times through novel design features and processes for marine energy composite structures. In this approach, not only can the composite mold be additively manufactured but it can also serve as part of the final load-bearing structure. We developed a conceptual design and implemented it to produce a reduced-scale additive/composite tidal turbine blade section to fully demonstrate the manufacturing possibilities. The manufacturing was successful and identified several critical features that could expedite the tidal turbine blade manufacturing process, such as single-piece construction, an integrated shear web, and embedded root fasteners. The hands-on manufacturing also helped identify key areas for continued research to allow for efficient, durable, and low-cost additive/composite-manufactured structures for future marine energy systems.

Prozessparameter beim Heißdrahtschneiden/Determination of proper process parameters for hot wire cutting with an industrial robot

Beim Heißdrahtschneiden werden Polystyrolschäume mit einem dünnen, erhitzten Metalldraht thermomechanisch bearbeitet. Der Prozess findet Einsatz im Modell- und Formenbau sowie im Rapid Prototyping. Das größte Potenzial wird der Technologie in der Architektur der Zukunft zugeschrieben. Dabei unterstützt diese den Handwerker bereits in der Entwicklungsphase, indem Prototypen schnell und kostengünstig erstellt und diskutiert werden können. Dies erfordert geeignete Prozessparameter.   In hot wire cutting, polystyrene foams are thermomechanically processed using a hot thin wire. The process is used in model and mold making as well as in rapid prototyping. A huge potential of the technology is foreseen with regard to the architecture of the future. This means, it is to support the craftsman already in the development phase by enabling prototypes to be created and discussed quickly and cost-effectively. This requires suitable process parameters.

Programming for Machining in Electrical Discharge Machine

The correct selection of manufacturing conditions is one of the most important aspects to take into consideration in most manufacturing processes and, particularly, in processes related to electrical discharge machining (EDM). It is a capable of machining geometrically complex or hard material components that are precise and difficult-to-machine such as heat-treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels, etc. being widely used in die and mold making industries, aerospace, aeronautics, and nuclear industries. This chapter highlights the programming for machining in electrical discharge machine.

CASTING: A METHOD OF ARCHAEOLOGICAL DATA RECORDING IN SAVING THE NATIONAL CULTURAL HERITAGE HISTORY VALUES

Casting sebutan lain dari penggandaan dalam dunia arkeologi. Casting diartikan sebagai upaya untuk merekam data yang ada pada suatu benda arkeologi secara akurat dalam bentuk tiga dimensi sehingga seluruh ukuran dan permukaan akan sama dengan benda aslinya. Pembuatan casting ini, dilakukan secara manual dengan melalui tiga tahapan. Tahapan pertama dilakukan pembuatan cetakan pola negatif, tahapan kedua dilakukan pembuatan cetakan positif, dan tahapan ketiga pendinginan serta pewarnaan. Berbicara mengenai casting, maka akan berfikir bagaimana teknik casting pada benda cagar budaya yang berukuran 0-7 cm dan berukuran kurang lebih 1 meter. Pembuatan casting benda-benda arkeologi bertujuan untuk kepentingan ilmu pengetahuan, tindakan penyelamatan, bahan pameran atau sebagai alat peraga pendidikan. Metode yang dilakukan di antaranya, pengumpulan data, pengelompokan data dan bereksperimen terhadap benda yang akan di casting. Pembuatan casting benda cagar budaya memiliki tahapan yang berbeda, tergantung tingkat kesulitan benda tersebut. Pembuatan casting termasuk upaya pendokumentasian dalam pekerjaan penyelamatan terhadap benda meskipun fisik bendanya sudah mulai rapuh atau rusak. Casting, a method of recreating an archaeological object, is intended to accurately record the existing data on that object from three-dimensional perspective. It allows the exactly same display as that of the original object. Generally speaking, casting consists of three manual stages: negative mold preparation, positive mold making and cooling and colorong. The current study focuses on objects measuring 0-7 cm and less than 1 meter. Making archaeological objects casting aims for the benefit of science, a heritage rescue, exhibition material or as educational aids. The methods employed in this research are data collection, data classification and actual experimenting on casting. The study indicates that casting has a wide range of processes, depending on the level of difficulty. Making casting is also an effort to recording in a work of saving objects even though the object has begun to become fragile or damaged.