MAS 863
How To Make (almost) Anything
2009

Molding and Casting

molding
   injection (sprue, runner, gate, vent, parting line, flashing)
   insert
   vacuum
   blow
   flexible, soft

materials
   latex
   polyurethane
   PDMS (polydimethylsiloxane)
   thermoplastic, thermoset polymers
   calcium sulfate
      desicant, coagulant, plaster, gypsum, drywall
   Portland cement
      calcium silicate, aluminum/iron oxide, calcium sulfate
   metal, ceramic powders
   low-temp alloys
   waxes
   gels
   food

additives
   fibers (tension, compression, composites)
   fillers: density, conductivity, flexibility, color, ...

mixing

deairing

curing
   polymerization
   cross-linking
   hydration
   endothermic, exothermic

demolding
   taper
   release agents
   deformation

machining
   tool types
   depth of cut
   toolpaths, axes
   mold parts
   tippy.cad
   hello.svg
   hello.png
   stl2png

assignment
   machine a mold and cast parts in it

guru
   molding and casting: Sarah

lab sections
   Tue 1:00: vacuum former (John)
   Tue 8:00P: Kenny
   Wed 9:30AM: Nadya
   Thurs 6:00: Jonathan

inventory
   Smooth-On
      5  PMC 121-30 DRY-Trial Size/24.72/$123.60
      5  PMC 121-30 WET-Trial Size/24.72/$123.60
   Wolcott Park
      5 Sylgard 184: Maker: Dow Corning 1.1 pound kit. $29.90 $149.50
   US Gypsum
      10   Hydrostone Super X - 1 Gallon Pail   $9.25   $99.25
   Blick Art Materials 
      10   33523-1005 INSTAMOLD COMPOUND, 12OZ   $6.92   $69.20
      5    33504-1925 FLEXWAX MATERIAL, 2.5LB    $14.99  $74.95
   Amazon.com 
      1 DeWalt DW788S 20" Variable Speed Scroll Saw with Stand and Light $449.99  
      1 Black and Decker CHV9600 9.6-Volt Cyclonic DustBuster $29.99
      1 Cuisinart TOB-175BC Convection Toaster Oven/Broiler, Brushed Chrome $178.85 
   McMaster-Carr 
      10 2388A71 Ss Pocket Rule Without Clip Or Depth Gauge Inch Decimal Graduations, 6" Length $5.01 Each $50.10
      1  1760T86 Compact Digital Bench Scale with Ss Platform 2000 Grams X 0.1 Grams, 70.55 oz X .005 oz $295.45 (needs converter outside of US)
      4  41865A-12 Scroll Saw Blade Regular Cut;.250" Width, .028" thk, 20 tpi, 12-pack  $5.11/pk $20.44
      5  9389K61/Nonabrasive Machinable Wax Hard Purple Bar, 1-1/4" Thick X 3-1/2" W X 12" L/$23.64 Each/$118.20
      2  1865T35 Plastic Cup Polypropylene, 2-1/2 oz, 2-3/8" Top OD X 1-5/8" H, Packs of 125 $7.03 Pack $14.06
      1  77985T54 6" Length Wooden Paint Stirrer, Packs of 500 $8.23 Pack $16.46
      2  52555T1 Nitrile Disposable Gloves Powder Free, 5 MIL Thick, 9-1/2" L, Large, Blue, Boxes of 100 $13.33 Box $26.66
      10 17805T81 Disposable Aluminum Weighing Dish Smooth Sides, 2-7/8" Diameter X 3/4" Depth, Packs of 100  $8.72 Pack  $43.60
      2  9060K53 Soft Tempered Aluminum Foil .001" Thick, 12" Width, 250' Roll $27.26 Each $54.52
   Carbide Depot 
      10   .010" EM SQ 4FL S/E SMG-0.03" LOC-1.5" OAL (GT 13550) $14.29 $142.90
      25   4FL SE 1/64 AlTiN COATED (SGS 30191) $15.24 $381.00(* for remote 
      locations, we suggest doubling this line item)
      10   4FL SE 1/32 AlTiN COATED (SGS 30192) $8.07 $80.70
      10   4FL SE 1/16 AlTiN COATED (SGS 30194) $7.33 $73.30  
      10   4FL SE 3/32 AlTiN COATED (SGS 30196) $7.06 $70.60  
      10   4FL SE 1/8 AlTiN COATED (SGS 30198) $6.54 $65.40
      10   4FL SE BALLNOSE 1/64 AlTiN COATED (SGS 30031) $19.69 $196.90  
      10   4FL SE BALLNOSE 1/32 AlTiN COATED (SGS 30032) $10.26 $102.60   
      10   4FL SE BALLNOSE 1/16 AlTiN COATED (SGS 30034) $9.25 $92.50
      10   4FL SE BALLNOSE 3/32 AlTiN COATED (SGS 30036) $9.25 $92.50  
      10   4FL SE BALLNOSE 1/8 AlTiN COATED (SGS 30038) $8.28 $80.28
   Staples 
      5  617688/Model RK5 Translucent Plastic Cold Cups, 5-oz, 100/Pack/$2.99 100/Pack/$14.95
      5  563562/TP10 Solo Plastic Party Cups, 10-oz./$6.79 50/Pack/$33.95
      5  494051/Model TP16 Solo Plastic Party Cups, 16-oz. Clear/$5.79 50/Pack/$28.95
      10 538868/Model 5320 Kimberly-Clark Utility Wipes, 9" x 10 1/2", 125/Pack/$3.79 125/Pack/$37.90
   Budnick Converting 
   West Marine