make mold prov.na

[nicola1985]

Hello.
I'm a mechanical engineering student.
for my thesis (of the level) I have to realize an impact attenuator for a sae formula car.

I made the design with solidworks 2010 and modeling fem and impact with the hyperworks package.

Now I have to physically realize this piece (composed thermoplastic matrix).

I don't know where to start and who to turn to for the construction of the mold.

the piece must be produced in 3-4 specimens (I care that it is economic).

thank you all for the precious help!

 

[nicola1985]

I forgot I have a 5-axis milling machine and for itself the shape is not complicated.
in order to limit the cost I would not make it in metal but in other material.
I thought about wood, but the milling company told me no.
Then I don't know what to do! !

 

[Il marangon]

I don't know what budget you have but an injection mold goes on a few tens of thousands of heuries, just so it's the piece.

I would advise you to see other fiberglass or carbon materials that could approach the characteristics of a thermoplastic.

the piece is not that you can do it in thermoforming? if you prices drop and the wooden mold could be suitable.

to make considerations you should see the design of what you want to achieve.

there is also the stereo lithography (printing 3d if you don't know what it is) but also the prices are not contained, tot € per gr. depending on the material to use

 

[nicola1985]

If you send me an e-mail, I'll pass it so you see it...

the piece is an impact attenuator of a sae formula car.

the project and realization represents my dissertation (level) and fits precisely in the uninacorse project of my university.

to the polytechnic of torino have done it by hand (but I do not understand how it is possible from a cad to work by hand with the necessary precision):
http://squadracorse-polito.com/index.php?option=com_exposeprive&topcoll=107Maybe you who are expert can explain how they did it!

we look for sponsors for the realization of this mold (while for the lamination in carbon and kevlar, we already have impact)

Thank you all!

 

[nicola1985]

I have a 5-axis milling machine...
I could use that to make the mold!

 

[Fulvio Romano]

but milling plastics? What do I know, teflon, or anything?
or a 3d print in abs... also here on the forum there is someone who can do it.

 

[nicola1985]

can all milling machines cut plastics?

For what I have at my disposal they have to let me know tonight!

Is there anyone who wants to sponsor our machine for the realization of this mold?

more information about www.uninacorse.com

 

[nicola1985]

I need to roll over the mold.. .

 

[nicola1985]

I thought I'd do it for milling.. Finally there is a company that sponsors the cost of the machine and the operator.

I have to carry only raw material. . .

I thought:
mdf
high density polystyrene
resin resin

what's better and where can I buy them?
Thank you!

 

[Fulvio Romano]

I thought I'd do it for milling.. Finally there is a company that sponsors the cost of the machine and the operator.

I have to carry only raw material. . .

I thought:
mdf
high density polystyrene
resin resin

what's better and where can I buy them?
Thank you!

resin?
all this (or almost) you get for polymerization is a resin. What are you talking about?

many resins also find them from the hardware store in beautiful white cubes. . .

You didn't clarify what you need this piece. just to see aesthetically how it comes? Do you have to put something on it?

 

[nicola1985]

At the end, I've got to put something against it.

This is the mold... I have to roll over or inside we see!
the final piece will be in carbon and kevlar.

 

[Fulvio Romano]

What is the carbon collection in polymerization? Are you sure that the soul does not induce residual tensions?
Anyway, now I understand what you have to do. you definitely need expanded polyurethane, cn cutters and laminate over it, as you do for the structures of the vessels in vtr.

the only thing you need to check is the chemical compatibility of the support with resin.

 

[nicola1985]

What is the carbon collection in polymerization? Are you sure that the soul does not induce residual tensions?
Anyway, now I understand what you have to do. you definitely need expanded polyurethane, cn cutters and laminate over it, as you do for the structures of the vessels in vtr.

the only thing you need to check is the chemical compatibility of the support with resin.

where can I buy expanded polyurethane?
Why did you recommend this to me?
Are all steel milling machines capable of working these materials?

Thank you!

 

[Il marangon]

Okay, so the piece doesn't seem complicated now you have to understand, as it says fulvio, what do you have to do with this...and big glove is?

if you only have to look at polystyrene can be fine, if you have to make it in fiberglass/carbon you have to create a mold... the beautiful side what is it? the outside or the inside?
If you have to do some castings with plastic-like resins, you have to make sting matrix, how many pieces?

What you designed is the mold? If you have to do it in polystyrene there are special tools and facts are for him to work it. . .
who has an iron/aluminum cutter lubricated usually not the "sporty" to work resins or mdf...

 

[Il marangon]

Now I've seen the last post...
I'll tell you

the beautiful side of the laminated piece that in contact with the mold for which you have to decide a priori which side of the piece you care that it is beautiful

decided we know how to create the mold

carbon or kevlar pieces have different molds depending on the technique used to make them, for example, if you go in autoclave you have to make an aluminum or carbon mold, you can also make it in resin but the suitable ones have a very close cost to that of aluminum itself
if you are aware of a vacuum you can also do it in mirror painted mdf or cheaper resins

At this point you should talk to who will make you the piece to understand what it needs

 

[Fulvio Romano]

Now I've seen the last post...
I'll tell you

the beautiful side of the laminated piece that in contact with the mold for which you have to decide a priori which side of the piece you care that it is beautiful

decided we know how to create the mold

carbon or kevlar pieces have different molds depending on the technique used to make them, for example, if you go in autoclave you have to make an aluminum or carbon mold, you can also make it in resin but the suitable ones have a very close cost to that of aluminum itself
if you are aware of a vacuum you can also do it in mirror painted mdf or cheaper resins

At this point you should talk to who will make you the piece to understand what it needs

All right.
I was talking about expanded polyurethane because it is light, and even if it stays inside is not a problem. I repeat, so do the structures of the boats.
of course with this technique, the side "beautiful"... is not there!

 

[nicola1985]

Okay, so the piece doesn't seem complicated now you have to understand, as it says fulvio, what do you have to do with this...and big glove is?

if you only have to look at polystyrene can be fine, if you have to make it in fiberglass/carbon you have to create a mold... the beautiful side what is it? the outside or the inside?
If you have to do some castings with plastic-like resins, you have to make sting matrix, how many pieces?

What you designed is the mold? If you have to do it in polystyrene there are special tools and facts are for him to work it. . .
who has an iron/aluminum cutter lubricated usually not the "sporty" to work resins or mdf...

it is not necessary to have the beautiful side as this piece is hidden from the hull.. .
Yes what I designed is the mold.
I had thought of making a spray fiberglass countertop and then laminating from the inside.

the pen is 380mm wide 260.

I would like to make the mold from the full...

 

[nicola1985]

Now I've seen the last post...
I'll tell you

the beautiful side of the laminated piece that in contact with the mold for which you have to decide a priori which side of the piece you care that it is beautiful

decided we know how to create the mold

carbon or kevlar pieces have different molds depending on the technique used to make them, for example, if you go in autoclave you have to make an aluminum or carbon mold, you can also make it in resin but the suitable ones have a very close cost to that of aluminum itself
if you are aware of a vacuum you can also do it in mirror painted mdf or cheaper resins

At this point you should talk to who will make you the piece to understand what it needs

as a polymerization process I will use a trivial vacuum. . .

 

[Il marangon]

Okay.

3 are alternatives:

mirror painted mdf mold

piece in polystyrene/polyurethane to be clad as it said fulvio

resin mold costs + but get a better product,
for the material I buy it here http://www.elantas.com/camattini/it/model_mould_systems.php?do=changelangor here but do not find the page with resins in tableshttp://www.sika.it/home/newpage/newpage-4.htmin all three cases I doubt that those who work iron will go to process these materials because of the powders that are created when brakes that intax the refrigerant filters for the tool.

 

[Fulvio Romano]

Okay.

3 are alternatives:

mirror painted mdf mold

piece in polystyrene/polyurethane to be clad as it said fulvio

resin mold costs + but get a better product,
for the material I buy it here http://www.elantas.com/camattini/it/model_mould_systems.php?do=changelangor here but do not find the page with resins in tableshttp://www.sika.it/home/newpage/newpage-4.htmin all three cases I doubt that those who work iron will go to process these materials because of the powders that are created when brakes that intax the refrigerant filters for the tool.

There are people who work hard mdf and epowood, I wouldn't shake the manufacturers of serious chips.. .

Perhaps, a solution could actually be, milling one of these materials, gelcoat hand, vile fiberglass mold (it should cost quite little). At that point you have a mold with a good internal finish, even if I don't think it can go in autoclave, but you say you don't need it.

made the mold, wash us in the carbon, kevlar, unbtanium, or the material you want.