MAS 863
How To Make (almost) Anything

Molding

molding:
   injection (sprue, runner, gate, vent, flashing)
   insert
   vacuum
   blow
   flex

materials:
   thermoplastic, thermoset polymers
   polyurethane
   PDMS (polydimethylsiloxane)
   latex
   plaster, calcium sulfate
   Portland cement, calcium silicates
   metal, ceramic powders
   waxes
   gels
   food

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

mixing

deairing

curing:
   polymerization
   cross-linking
   hydration
   endothermic, exothermic

demolding:
   taper
   release agents
   deformation

applications:
   Neri, Kenny, Manu

assignment:
   make a mold and cast parts in it
   mold.cad
   mold.png

inventory:
   http://plaster.com/
   10   Hydrostone Super X - 1 Gallon Pail   $9.25   $99.25
   10   Drystone - 1 Gallon Pail             $9.75   $99.75
   
   http://www.smooth-on.com/
   10   PMC-121/30 DRY - 2 lbs   $22.00   $220.00
   
   http://www.dickblick.com/
   10   33523-1005 INSTAMOLD COMPOUND, 12OZ   $6.92   $69.20
   5    33504-1925 FLEXWAX MATERIAL, 2.5LB    $14.99  $74.95
   
   http://www.wolcott-park.com
   PDMS
   5 Sylgard 184: Maker: Dow Corning 1.1 pound kit. $29.90 $149.50

   http://www.westmarine.com
   2  9860008 MAS Low Viscosity Resin, 1 Quart 2.70 lb $29.99 USD $59.98 USD  	
   2  9860198 Mas Medium Hardener, 1 Pint 0.60 lb $20.99 USD $41.98 USD  	
   1  190027 Fiberglass Cloth - Density (6 OZ), 38" x 90 3.00 lb $39.99 $39.99
   1  9860321 Colloidal Silica, .5 Gallon 0.15 lb $15.99 USD $15.99 USD  	
   1  9860404 Mas Phenolic Micro Balloon Filler, 1/2 Gallon 0.10 lb $32.99 USD $32.99 USD  	
   1  9860438 Mas Wood Flour Filler, 1/2 Gallon 0.20 lb $13.99 USD $13.99 USD  	
   1  9860354 Mas Cell-O-Fill Filler, 1/2 Gallon 0.45 lb $9.99 $9.99
   1  9860388 Mas Milled Fibers Filler, 1/2 Gallon 2.65 lb $37.99 USD
   1  323659 423 Graphite Powder - 12 OZ 1.00 lb $15.99 USD $15.99 USD  	
   1  323634 420 Aluminum Filler - 1 LB 1.28 lb $20.99 USD $20.99 USD  	
   2  184788 Resin Coloring Agent - Admiral Blue 0.24 lb $9.99 $19.98
   2  184747 Resin Coloring Agent - Red 0.38 lb $9.99 $19.98
   2  5399977 Home Dust Mask 15 Pack 0.68 lb $15.99 USD   

   http://www.carbidedepot.com/
   10   4FL SE 1/8 AlTiN COATED (SGS 30198) $6.54 $65.40
   10   4FL SE BALLNOSE 1/8 AlTiN COATED (SGS 30038) $8.28 $80.28
   
   http://www.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
   
   http://www.mcmaster.com/
   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
   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
   1 7074T62 Swab Cotton-Low Lint Tip,.141" Diam X .44" L Tip, 6" L O'all, 1000/pk  $18.75/ Pack 
   2 52555T1 Nitrile Disposable Gloves Powder Free, 5 MIL Thick, 9-1/2" L, Large, Blue, Boxes of 100 $13.33 Box $26.66
   4 41865A-14 Scroll Saw Blade Fast Cut Skip Tooth, .029" W, .012" thk, 20 tpi, 12-pack $4.78/pk $19.12
   4 41865A-16 Scroll Saw Blade Fast Cut Skip Tooth, .100" W, .022" Thk, 9 Tpi, 12 pack  $5.33/pk $21.32
   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
   
   http://www.staples.com
   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
   5  617688/Model RK5 Translucent Plastic Cold Cups, 5-oz, 100/Pack/$2.99 100/Pack/$14.95
   10 538868/Model 5320 Kimberly-Clark Utility Wipes, 9" x 10 1/2", 125/Pack/$3.79 125/Pack/$37.90