MEAM.Design - IPD 501 - MOLD


Mold

Dates
Urethane Casting
Tu J30: Assigned

- Project introduction.

Th F01: Mold: UC PDR

- Be prepared to discuss three complete ideas for the project.
- Compile sketches, brief size estimates, and required materials for the three designs IN A SINGLE .pdf. and email this to medesign@seas.upenn.edu by 2:00pm before class. Title both the file and email as "501-MOLD-PDR-SKETCHES-PennKey1_Pennkey2".
- Watch the videos in the Freeman video library on urethane casting.
- Urethane Casting Demo

Tu F06: Mold: UC CDR

- Create an exploded view of your part and mold, saved as a PDF, and email along with a pack-and-go assembly of your part and model to medesign@seas.upenn.edu by 2:00PM before class. Title the pack-and-go assembly as "501-MOLD-PDR-ASSEMBLY-PennKey1_Pennkey2". Title both the PDF file and email as "501-MOLD-CDR-ASSEMBLY-PennKey1_PennKey2".
- Using the specifications on the Freeman website, calculate how much by weight (lbs) and volume (in3) of each silicone+catalyst and elastomer resin+hardener you will need for your mold and part, respectively. Include this in the body of the email and in your PDF.
- Be prepared to discuss your considerations for how you will make this part from urethane and how you plan to design and make an injection mold for the same part.
- Submit your 3D printed part as an STL to print3d@seas.upenn.edu by the end of the day. Follow the instructions for 3D printing requests as found on MEAMLabs. The recommended machine will be the ProJet6000 with the Visijet clear material and the payment source should be IPD501. Make sure to CC medesign@seas.upenn.edu in the email.

Tu F13: Mold: UC Due

- Bring your completed silicone mold and at least 2 urethane cast parts to class at 3:00PM.

Th F15: Mold: UC Canvas Reflection Due

- Complete the Canvas reflection for Urethane Casting by 2:00PM before class.


Injection Molding
Tu F06: Assigned

- Project introduction.

Th F08: No Class

Tu F13: Design for Injection Molding

- JD Albert Guest Lecture
- Create an updated version of your part that is suitable for injection molding, along with a high quality 1400x1050 pixel JPG rendering of your part.
- Follow the activities in the SolidWorks Plastics Guide and run an injection molding simulation. Save plots from step 13 and take screenshots from step 14 with the demo part found below as well as your updated part.
- Create a PDF with the rendering of your updated part and images from your injection molding simulations of the demo part and your updated part.
- Email the PDF as an attachment to medesign@seas.upenn.edu by 2:00PM before class. Title both the PDF file and email as "501-IM-MOLD-PDR-SUBMISSION-PennKey1_PennKey2". Discuss in the body of the email what changes you made and why.

Th F15: Mold: IM CDR, CAM Reviews Begin, Machining Begins

- Be prepared to discuss your considerations for how you will design and make an injection mold for your part.
- Create a pack-and-go assembly of your part and completed mold and title this folder "501-IM-MOLD-CDR-ASSEMBLY-PennKey1_PennKey2".
- Create an exploded view of your part and mold using Keyshot, saved as a PDF along with fully defined engineering drawings using GD&T, and email, along with the pack-and-go assembly of your part and mold, to medesign@seas.upenn.edu by 2:00PM before class. Title both the .PDF file and email as "501-IM-MOLD-CDR-SUBMISSION-PennKey1_PennKey2".

Tu F20: Injection Molding Demo

- Injection Molding Demo

Th M1: Mold: IM Due

- Bring your completed molds and 10 injection molded parts to class at 3:00PM.

Fr M2: Mold: IM Canvas Reflection Due

- Complete the Canvas reflection for Injection Molding by 11:59PM.


Assignment
In groups of two, design and manufacture an injection molded part that interfaces with another component.
1. Use urethane casting to prototype and evaluate the part and mold.
2. Design and machine an aluminum mold for injection molding. Injection mold at least 10 copies of your part.

Deliverables
1. At least 2 urethane cast prototypes of your part.
2. At least 10 injection molded copies of your part.
3. Engineering drawings of your part and molds.

Guidelines

  • For urethane casting we will print the tool on the ProJet 6000 HD, and you will cast your mold from silicone.
  • Watch the following videos on the Freeman website:
- All 4 videos in the "Section 1 - Preparing Models & Molds" section
- Simple Silicone Rubber Molds (no parting line)
- Two-Part Silicone Rubber Molds (with a straight parting line)
  • For injection molding you will machine your entire mold from aluminum on the Mini Mill.

Materials
Urethane Casting:

Injection Molding:

  • Stock: 5"x1-1/2" 6061 aluminum bar
  • Resin: HDPE
  • Dowel Pins: 3/16"x1"

Setup

  • Parts will be designed to fit within a 5" x 5" x 3" box.
  • Your injection molding tooling should have at least a 0.5" wall thickness in X, Y, and Z.
  • Your mold will need a 1/8" deep, 1" diameter concave pocket to accommodate the outside of the nozzle. A 1" ball endmill will be provided for this.
  • The ID of the nozzle is 5/32". A 3/16" 2° tapered end mill will be provided for the sprue in your mold.
  • We will be using the same tool table from Candy. You will need to define any other tools you will be using in the tool table, however tools #2 and #3 should not be changed. When defining the tool holder, use an oversized tool holder such as the 1" toolholder—this will guarantee that the spindle will not crash into your part.
  • The following HSS tapered end mills are available for use in creating your molds:
Tool Flutes Taper Length of Cut (in) Arbor Diameter (in) Quantity
1/2" Square 3 1° 1.250" 0.500" 1
3/8" Square 3 3° 1.250" 0.500" 1
1/4" Square 3 1° 1.250" 0.375" 2
3/16" Square 3 2° 1.250" 0.375" 2
1/8" Square 3 1° 1.250" 0.375" 3
3/32" Square 3 1° 0.750" 0.375" 0
1/4" Ball 3 1° 1.250" 0.375" 2
1/8" Ball 3 1° 1.000" 0.375" 2



Resources


Some Questions

  • You will have created at least three versions of your part during this project: 3D printed, urethane cast, and injection molded. What are the differences between the three versions of your part and how did each influence the final design of your part? What aspects of the final part and process were not enveloped by the two prototype parts?