Because my final project will deal with sound and acoustics, I decided to explore the possibility of making different kinds of acoustic panels. In particular, I was interested in mixing contrasting materials - hard+soft for example.
I used the ShopBot to surface mill a mold since there was a shortage of wax.
SettingsEnd Mill 1/4" down-cut
Speed 10,000 rpm
Feed Rate 100
Plunge Rate 40
I also milled a larger mold using high-density foam, into which the smaller cast components would fit
I coated the 'container'with sandable-gesso and then...sanded it.
I added weep holes to the mold so that I could lessen the chance of air-pockets
The pieces I cast in the foam were not very accurate and for smaller components, totally unusable
I used the large gesso covered mold to hold the smaller cast pieces, as well as some ear-plugs - it is supposed to be an acoustic panel after all.
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