04 – Casting – Crystal module [Process]

:: Design – Crystal module

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To cast an object successfully, one must understand well the process of casting and the limitation of the tools.

Process of casting:

Step 1 – to mill the positive of the object in parts

Step 2 – to create a negative mold from the positive mill

Step 3 – to cast the positive

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For this project, the geometry of the rhomboid cannot be casted with a straight forward 2 parts mold. This is because undercuts will be created in the positive mill.

Therefore, a six parts mold was designed to avoid all possible undercuts.

:: Step 1 – Milling

:: Machine – Techno CNC

Thickness of foam – 1.5″

Drill bit – 1/4 flat end

Horizontal roughing – 200% diameter step over and 200% step down

Parallel finishing – 15% step over

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:: Step 2 – Mold making

:: Tools and materials – Sanding paper, Gesso, soap, 25 Mold Star

Before making the mold out from the milled positive, it was first sanded and then applied gesso and soap water.

25 Mold Star, Part A and Part B

Temporary chip board registration rings were cut from lasercutter for holding the 6 parts mold tight together.

A small self made funnel device was made for better pouring of the liquid.

After 10 minutes, the cast is ready. The extra part from the ventilation hole has to be cut after casting. Corners have to be sanded as well.

Final products