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VIDEO TUTORIAL

PRODUCTEN GEBRUIKT IN DIT PROJECT

Hoewel dit niet noodzakelijkerwijs een volledige lijst is, zijn de volgende gereedschappen en materialen, geleverd door Easy Composites, gebruikt in dit project.

De hieronder getoonde hoeveelheid is de hoeveelheid die bij benadering in het project is gebruikt, naar boven afgerond op de dichtstbijzijnde beschikbare kitmaat of hoeveelheid.

MATERIALEN & VERBRUIKSARTIKELEN
EP700 High Temp Epoxy Tooling Board T=50mm, 500 x 500mm Thumbnail
EB700-025-50EP700 High Temp Epoxy Tooling Board T=50mm, 500 x 500mm€231.80 /block

Nitril Handschoenen - Set van 10 Duimnagel Groot
NG-L-10Nitril Handschoenen - Set van 10 Groot€1.75 /verpakking

Mirka 800 Schuurpapier voor nat en droog 10 Vellen Duimnagel
WPF800-10Mirka P800 nat en droog schuurpapier 10 vellen€8.30 /verpakking

Pluisvrije oplosmiddeldoekjes 50 doekjes Duimnagel
LFW-50Niet-pluizende oplosmiddeldoekjes 50 doekjes€9.85 /verpakking

Spuitkop voor 50ml en 250ml fles Duimnagel
SN-24-BLKSpuitkop voor 50ml en 250ml fles€1.10 /per stuk

S120 Advanced Board & Mould Sealer 50ml met spuitmond Duimnagel
S120-005S120 Advanced Board & Mould Sealer 50ml with Nozzle€20.20 /pack

Totaal €0,00

VIDEO TUTORIAL

CNC verspanen van 3D CAD patronen en mallen uit Epoxy Tooling Board

Video tutorial demonstrating how a 3D CAD design can be machined from epoxy tooling board on a CNC router to produce a highly accurate pattern or mould. Includes how to hand finish, seal and gloss the pattern using S120 board sealer.

In the tutorial we use a desktop CNC router to machine a block of our EB700 Epoxy Tooling Board. The original 3D design was done in Autodesk's Fusion360 CAD programme.

Once the machining is complete we use 800 grit Mirka abrasive paper to do some light flatting to smooth the surface of the pattern. We then spray four coats of S120 Advanced Board & Mould Sealer before flatting the surface again using more 800 grit abrasive paper before bringing the pattern to a full gloss finish using four wipe applications of the S120 board sealer.


UITSPLITSING TUTORIAL

CNC machining

1. CNC machining

Het ontwerp werd getekend met Fusion 360 voordat het CNC werd gesneden met een desktop CNC-router. Voor toepassingen als deze was de 6 mm frees ideaal en deze sneed de plaat gemakkelijk. Nadat de eerste grove zaagsneden waren gemaakt, werden de afwerkingssneden gemaakt met een stap van 0,25 mm voor een goede afwerking.

Hand finishing

2. Hand finishing

Het bewerkingsproces laat zeer kleine bewerkingssporen achter op het oppervlak van het patroon. Deze moeten worden gladgemaakt door het patroon met de hand af te werken met schuurpapier tot de afwerking glad is. Voor het sealen moet je het stof goed afnemen met een doek.

Board sealer

3. Board sealer

Deze fase is bedoeld om het oppervlak van het patroon te verzegelen en tot een perfecte hoogglans te brengen, klaar om de mal uit te nemen. In eerste instantie worden lagen S120 Board sealer aangebracht met behulp van de sproeikop om te helpen afdichten en een egale laag op te bouwen. Er zijn tussen de 3 en 5 lagen nodig voor een typische epoxyplaat.

Nadat de 4e laag enkele uren heeft kunnen drogen, kun je de afwerking van de plank met schuurpapier denibben en gladmaken. Eenmaal glad wordt de laatste laag aangebracht met een pluisvrije doek voordat de sealer droogt. Eenmaal uitgehard kan het patroon worden nagehard in de oven om het klaar te maken voor het maken van de mal.


DISCUSSIE (12)

Laat het ons weten als je vragen of opmerkingen hebt over deze videotutorial.


Johnathan Parra
Is there an alternative to sealing the tooling board using a board sealer? Can I use resin?
Gemakkelijk samenstellenMat

Yes, you could also use a thin layer of resin to seal the board if you don't want to use a specific board sealer (like S120). Resin will build a bit thicker and therefore need a bit more flatting to restore a flat, accurate surface. A good choice would be our XCR Epoxy Coating Resin - it goes on thin, cures quickly to a high gloss, and is highly polishable. The working temperature of the XCR is lower than the board sealer but it’s still fine for use up to 80°C.


Ganesh Hosur
Can the pattern be reused?
Gemakkelijk samenstellenMat
Yes, providing no damage occures to the pattern during curing or demoulding then the pattern can be retained and used again to make more moulds. This would be quite a common way to make multiple moulds or replace an old, damaged mould.

Bill Vardouniotis
Which CNC machine is used in this video?
Gemakkelijk samenstellenMat
It's a CNCEST 60/40.

andres cintron
Any consideration of making a mold using a 3D printer?
Gemakkelijk samenstellenMat
As long as the surface is sealed to stop any issues of porosity, then for some applications it may be possible to 3D print a mould. However the material needs to be suitable for curing with pre-preg if you follow that route.

MySchizoBuddy
What is the technical name of epoxy tooling board? High density urethane foam ?
Gemakkelijk samenstellenMat
No, definitely not. The epoxy tooling board is made from epoxy. In this video we're using our EB700 Epoxy Tooling Board. We don't use polyurethane tooling board because polyurethane inhibits the cure of epoxy prepregs. Also, for this type of work you really need to talking of tooling board or block rather than 'foam' which would generally imply a much lower density material than we're using here.

Lee Jack
Can patterns be made from 3D printed PLA or ABS plastic with post surface treatment?
Gemakkelijk samenstellenMat
Hi Lee, yes, there are ways to do this. In fact, there is a lot of interest in this subject at the moment so we are looking into some of the best methods and processes to demonstrate and then we hope to make a tutorial of this process in the future.

J. Dana Clark
Assuming ideal treatment and conditions, how many molds would you expect to get off of that plug?
Gemakkelijk samenstellenMat
You could comfortably take in the 10's to 20's - maybe a lot more in 'ideal conditions'. In this video, the mould was already off the plug by the time we took the bagging film off so I think it's safe to say we could keep taking moulds off with almost no damage or deterioration of the pattern.

RTGood1
How did you map the dimensions of the original casing in order for the CNC to be able to produce the mould?
Gemakkelijk samenstellenMat
The original shape was drawn in CAD from scratch.

Beach&BoardFan
So once that S120 finish wears off from use, can more coatings of it be applied so the mold can be reused again and again?
Gemakkelijk samenstellenMat
Yes you can restore the finish with fresh applications of the S120 Board Sealer.

Benjamin Whiffen
Wow I was just about to begin to do this thank for the video. Do you know if insulation foam can work because I need to make a huge mold and accuracy is not key.
Gemakkelijk samenstellenMat
You could use insulation foam to make a rough shape but to be usable in any form you would then need to add strength to the structure, normally by 'scrimming' it with glass fibre and resin (make sure you use epoxy resin like our EL2, not polyester or vinylester because they will melt your foam) and then coating the pattern using a high-build pattern coat (such as our Pattern-Coat Primer). You could then use the S120 Board Sealer over the top of the pattern coat primer to bring it to a full gloss.

Derick Deitz
How would you vacuum bag a two part mold such as the tooling board mold that you guys showed for the 90 degree pipe fitting. I’m interested in how to bag it so I’d get proper adhesions of the two halves.
Gemakkelijk samenstellenMat

Please take a look at our tutorial on vacuum bagging a split-moulded carbon fibre tube component, I think this covers just what you're looking for!


David Xu
How to strength the places where two moulds join together, for example, the 90 degree rotating pipe, if you lay fabric on each mould, when you join them together, the only connected is the resin instead of fabric, then how to strengthen them?
Gemakkelijk samenstellenMat
You can do that in the manufacturing process, or even laminate carbon tape or fabric over the join to make it stronger afterwards. A bit of careful thought during the planning phase can mean you do the overlapping as the part is made, making things simpler and quicker overall.

LAAT EEN OPMERKING OF VRAAG ACHTER

Opmerking: Je naam zal worden afgekort en je e-mailadres zal alleen worden gebruikt om je het antwoord direct te mailen.

PRODUCTEN GEBRUIKT IN DIT PROJECT

Hoewel dit niet noodzakelijkerwijs een volledige lijst is, zijn de volgende gereedschappen en materialen, geleverd door Easy Composites, gebruikt in dit project.

De hieronder getoonde hoeveelheid is de hoeveelheid die bij benadering in het project is gebruikt, naar boven afgerond op de dichtstbijzijnde beschikbare kitmaat of hoeveelheid.

MATERIALEN & VERBRUIKSARTIKELEN
EP700 High Temp Epoxy Tooling Board T=50mm, 500 x 500mm Thumbnail
EB700-025-50EP700 High Temp Epoxy Tooling Board T=50mm, 500 x 500mm€231.80 /block

Nitril Handschoenen - Set van 10 Duimnagel Groot
NG-L-10Nitril Handschoenen - Set van 10 Groot€1.75 /verpakking

Mirka 800 Schuurpapier voor nat en droog 10 Vellen Duimnagel
WPF800-10Mirka P800 nat en droog schuurpapier 10 vellen€8.30 /verpakking

Pluisvrije oplosmiddeldoekjes 50 doekjes Duimnagel
LFW-50Niet-pluizende oplosmiddeldoekjes 50 doekjes€9.85 /verpakking

Spuitkop voor 50ml en 250ml fles Duimnagel
SN-24-BLKSpuitkop voor 50ml en 250ml fles€1.10 /per stuk

S120 Advanced Board & Mould Sealer 50ml met spuitmond Duimnagel
S120-005S120 Advanced Board & Mould Sealer 50ml with Nozzle€20.20 /pack

Totaal €0,00

DISCUSSIE (12)

Laat het ons weten als je vragen of opmerkingen hebt over deze videotutorial.


Johnathan Parra
Is there an alternative to sealing the tooling board using a board sealer? Can I use resin?
Gemakkelijk samenstellenMat

Yes, you could also use a thin layer of resin to seal the board if you don't want to use a specific board sealer (like S120). Resin will build a bit thicker and therefore need a bit more flatting to restore a flat, accurate surface. A good choice would be our XCR Epoxy Coating Resin - it goes on thin, cures quickly to a high gloss, and is highly polishable. The working temperature of the XCR is lower than the board sealer but it’s still fine for use up to 80°C.


Ganesh Hosur
Can the pattern be reused?
Gemakkelijk samenstellenMat
Yes, providing no damage occures to the pattern during curing or demoulding then the pattern can be retained and used again to make more moulds. This would be quite a common way to make multiple moulds or replace an old, damaged mould.

Bill Vardouniotis
Which CNC machine is used in this video?
Gemakkelijk samenstellenMat
It's a CNCEST 60/40.

andres cintron
Any consideration of making a mold using a 3D printer?
Gemakkelijk samenstellenMat
As long as the surface is sealed to stop any issues of porosity, then for some applications it may be possible to 3D print a mould. However the material needs to be suitable for curing with pre-preg if you follow that route.

MySchizoBuddy
What is the technical name of epoxy tooling board? High density urethane foam ?
Gemakkelijk samenstellenMat
No, definitely not. The epoxy tooling board is made from epoxy. In this video we're using our EB700 Epoxy Tooling Board. We don't use polyurethane tooling board because polyurethane inhibits the cure of epoxy prepregs. Also, for this type of work you really need to talking of tooling board or block rather than 'foam' which would generally imply a much lower density material than we're using here.

Lee Jack
Can patterns be made from 3D printed PLA or ABS plastic with post surface treatment?
Gemakkelijk samenstellenMat
Hi Lee, yes, there are ways to do this. In fact, there is a lot of interest in this subject at the moment so we are looking into some of the best methods and processes to demonstrate and then we hope to make a tutorial of this process in the future.

J. Dana Clark
Assuming ideal treatment and conditions, how many molds would you expect to get off of that plug?
Gemakkelijk samenstellenMat
You could comfortably take in the 10's to 20's - maybe a lot more in 'ideal conditions'. In this video, the mould was already off the plug by the time we took the bagging film off so I think it's safe to say we could keep taking moulds off with almost no damage or deterioration of the pattern.

RTGood1
How did you map the dimensions of the original casing in order for the CNC to be able to produce the mould?
Gemakkelijk samenstellenMat
The original shape was drawn in CAD from scratch.

Beach&BoardFan
So once that S120 finish wears off from use, can more coatings of it be applied so the mold can be reused again and again?
Gemakkelijk samenstellenMat
Yes you can restore the finish with fresh applications of the S120 Board Sealer.

Benjamin Whiffen
Wow I was just about to begin to do this thank for the video. Do you know if insulation foam can work because I need to make a huge mold and accuracy is not key.
Gemakkelijk samenstellenMat
You could use insulation foam to make a rough shape but to be usable in any form you would then need to add strength to the structure, normally by 'scrimming' it with glass fibre and resin (make sure you use epoxy resin like our EL2, not polyester or vinylester because they will melt your foam) and then coating the pattern using a high-build pattern coat (such as our Pattern-Coat Primer). You could then use the S120 Board Sealer over the top of the pattern coat primer to bring it to a full gloss.

Derick Deitz
How would you vacuum bag a two part mold such as the tooling board mold that you guys showed for the 90 degree pipe fitting. I’m interested in how to bag it so I’d get proper adhesions of the two halves.
Gemakkelijk samenstellenMat

Please take a look at our tutorial on vacuum bagging a split-moulded carbon fibre tube component, I think this covers just what you're looking for!


David Xu
How to strength the places where two moulds join together, for example, the 90 degree rotating pipe, if you lay fabric on each mould, when you join them together, the only connected is the resin instead of fabric, then how to strengthen them?
Gemakkelijk samenstellenMat
You can do that in the manufacturing process, or even laminate carbon tape or fabric over the join to make it stronger afterwards. A bit of careful thought during the planning phase can mean you do the overlapping as the part is made, making things simpler and quicker overall.

LAAT EEN OPMERKING OF VRAAG ACHTER

Opmerking: Je naam zal worden afgekort en je e-mailadres zal alleen worden gebruikt om je het antwoord direct te mailen.

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