For composites, I wanted to do a spiral structure the negative of which could be used as a pen/pencil holder.
Software Rhino
Machine SHopbot
Material Foam, Epoxy
Hours 9
I modelled it in rhino. However, there were a few glitches in my design. The cuboids were too close to each other. As the endmill we use to mill foam is 1/2 inches, the minimum gap between two tollpaths should be atlease 0.75 inches. And the job was also taking a really long time. SO I scaled down the model by removing a few bocks and reducing the size as such.
Milling in progress.
Applying paste wax on the foam before pouring epoxy. this prevents the foam from burning.
After pouring epoxy. It immediately started forming bubbles.
As you can see the end result was a big blob of mess. It became so hard that I wasnt able to remove the mold.