Stop Silicone Cure Inhibition, No Fancy Or Expensive Products Required

Casting parts in silicone is great, and 3D printing in resin is fantastic for making clean shapes, so it’s natural for an enterprising hacker to want to put the two together: 3D print the mold, pour in the silicone, receive parts! But silicone’s curing process can be inhibited by impurities. What’s cure inhibition? It’s a gross mess as shown in the image above, that’s what it is. Sadly, SLA-printed resin molds are notorious for causing exactly that. What’s a hacker to do?

Firstly: there are tin-cure and platinum-cure silicones, and for the most part tin-cure silicone works just fine in resin-printed molds. Platinum-cure silicones have better properties, but are much more susceptible to cure inhibition. Most workarounds rely on adding some kind of barrier coating to molds, but [Jan Mrázek] has a cheap and scalable method of avoiding this issue that we haven’t seen before. Continue reading “Stop Silicone Cure Inhibition, No Fancy Or Expensive Products Required”

Casting Parts In Urethane: Tips From A Master

When you want a couple copies of a thing, you can 3D print ’em. When you want a ton of them, you might consider making a mold. If those are the shoes you’re in, you should check out this video from [Robert Tolone] (embedded below). Or heck, just check out all of his videos.

Even just in this single video from a couple years back, there are a ton of tips that’ll help you when you’re trying to pour resin of just the right color into a silicone mold. Mostly, these boil down to testing everything out in small quantities before pouring it in bulk, because a lot changes along the way. And that’s where [Robert]’s experience shines through — he knows all of the trouble spots that you need to test for.

For instance? Color matching. Resin dyes are incredibly concentrated, so getting the right amount is tricky. Mixing the color at a high concentration first and then sub-diluting it slowly allows for more control. But even then, the dried product is significantly lighter than the mixture, so some experimentation is necessary. [Robert] sneaks up on just the right color of seafoam green and then pours some test batches. And then he pours it in the exact shape of the mold just to be sure.

That’s just one of the tips in this video, which is just the tip of the mold-casting iceberg. Pour yourself a coffee, settle down, and you’ll learn something for sure. If you’re into more technical parts and CNC machining, we still love the Guerilla Guide after all these years.

Much thank to [Zane] for tipping us off to this treasure trove.

Continue reading “Casting Parts In Urethane: Tips From A Master”

A Rotocasting Machine Sized For The Home Shop

If you’ve ever wondered how large, hollow plastic structures like tanks and drums are formed, you’re in luck: [Andy] not only fills us in on the details of rotational casting and molding, but he also built this sweet little rotational casting machine to help him with his DIY projects.

Granted, [Andy]’s build won’t be making anything too large, like a car fuel tank or a kayak. Not only is it sized more for smallish parts, but those structures are generally made with the related process of rotational molding. Both processes use an enclosed multipart mold that’s partially filled with plastic resin, and then rotate the mold around two axes to distribute a thin layer of resin around the inside of the mold. The difference is that roto-molding uses a thermoplastic resin, whereas roto-casting uses resins like polyurethane and silicone that set at room temperature.

The machine looks simple, but only because he took great pains to optimize it. The videos below cover the build in detail — feel free to skip to the 11:38 mark of the second video if you just want to see it in action. Though you’ll be missing some juicy tidbits, like welding a perfect 90° joint in square tubing. There’s also the custom tool [Andy] built to splice the beaded chain he used to drive the spinning of the mold, which was pure genius.

Using the machine and a complex nine-piece mold, [Andy] was able to create remarkably detailed tires for RC cars from polyurethane resin. We’d love to see what else this rig is good for — almost as much as we want to see details on how the mold was made. We’ve seen other rotational casting machines before, but this one takes the cake for fit and finish.

Continue reading “A Rotocasting Machine Sized For The Home Shop”

3D Printed Molds For Casting Rose’s Metal

Have you ever played with Rose’s metal? It’s a fusible alloy of bismuth, lead, and tin with a low melting point of around 100 °C. Historically, it’s been used as a solder for cast iron railings and things, and as a malleable pipe filler material to prevent crimping while a pipe is bent.

[Ben Healey] has been playing around with Rose’s metal and some PETG printed molds, making everything from Star Wars Imperial credits to chess pieces to leather stamping tools. In the video after the break, [Ben] takes us through the process, beginning with mold-making from STLs — something he picked up from another YouTuber.

He recommends adding registration marks to multi-part molds in order to keep everything lined up, and adding a small recess in the seam for easy separation with a flat-head screwdriver. So far, the molds have held up to multiple pours, though [Ben] did print them rather thick and is glad he did.

As far as making liquid metal, [Ben] used a cast iron pot with a convenient pour spout, and a blowtorch. He added graphite powder to the molds in an effort to make them give up the goods more easily. To finish the pieces, [Ben] cut the flashing with tin snips and used sandpaper and a Dremel to smooth the edges. Copper plating didn’t work out, but [Ben] is going to try it again because he thinks he screwed something up in the process. He’s also going to try printing with TPU, which we were just about to recommend for its flexibility.

There are many ways to cast metal on the (relatively) cheap. Have you considered Kinetic Sand?

Continue reading “3D Printed Molds For Casting Rose’s Metal”

Epoxy lenses

The Ins And Outs Of Casting Lenses From Epoxy

If you need a lens for a project, chances are pretty good that you pick up a catalog or look up an optics vendor online and just order something. Practical, no doubt, but pretty unsporting, especially when it’s possible to cast custom lenses at home using silicone molds and epoxy resins.

Possible, but not exactly easy, as [Zachary Tong] relates. His journey into custom DIY optics began while looking for ways to make copies of existing mirrors using carbon fiber and resin, using the technique of replication molding. While playing with that, he realized that an inexpensive glass or plastic lens could stand in for the precision-machined metal mandrel which is usually used in this technique. Pretty soon he was using silicone rubber to make two-piece, high-quality molds of lenses, good enough to try a few casting shots with epoxy resin. [Zach] ran into a few problems along the way, like proper resin selection, temperature control, mold release agent compatibility, and even dealing with shrinkage in both the mold material and the resin. But he’s had some pretty good results, which he shares in the video below.

[Zach] is clear that this isn’t really a tutorial, but rather a summary of the highs and lows he experienced while he was working on these casting methods. It’s not his first time casting lenses, of course, and we doubt it’ll be his last — something tells us he won’t be able to resist trying this all-liquid lens casting method in his lab.

Continue reading “The Ins And Outs Of Casting Lenses From Epoxy”

Making A Metal Hand Doorknob

Regular doorknobs are widely reviled for their bare simplicity, but by and large society has so many other problems that it never really comes up in day to day conversation. Fear not, however, for [Matthew] has created something altogether more special: a doorknob in the shape of his own outstretched hand.

The build was inspired by a similar doorknob at the WNDR museum in Chicago, and its one you can recreate yourself, too. It’s achieved through a multi-stage mold making process. [Matthew]’s first step was to make a flexible mold of his hand using Perfect Mold alginate material to do so.

Once solidified, [Matthew’s] hand was removed and the mold filled with wax. The wax duplicate of [Matthew]’s hand was then used to create an investment plaster mold for casting metal. Vents were added in the end of each fingertip in the mold to allow molten metal to effectively fill the entire cavity.

Once the investment mold was solid and dry, the wax was melted out and it was ready for casting. A propane furnace was used to melt the casting metal and fill the mold using a simple gravity casting method. [Matthew] ended up making two hands, one in aluminium and one in copper. Some cleanup with grinders and a wire wheel, and a replica of [Matthew]’s hand was in his hands!

The finished piece looks great attached to a door knob, and we’re sure it’s quite satisfying shaking hands with your hefty metal self every time you open the door. It bears noting that the same techniques can be used with 3D printing, too! If you pull off your own great home casting project, be sure to drop us a line. Video after the break.

Continue reading “Making A Metal Hand Doorknob”

Hackaday Links Column Banner

Hackaday Links: September 19, 2021

Things might be getting a bit dicey out in Jezero crater for Ingenuity. The little helicopter that could is starting to have trouble dealing with the thinning Martian atmosphere, and may start pressing against its margin of safety for continued operation. Ingenuity was designed for five flights that would all take place around the time its mothership Perseverance touched down on Mars back in February, at which time the mean atmospheric pressure was at a seasonal high. Over the last few months, the density of the Martian atmosphere has decreased a wee bit, but when you’re starting with a plan for a pressure that’s only 1.4% of Earth’s soupy atmosphere, every little bit counts. The solution to keeping Ingenuity flying is simple: run the rotors faster. NASA has run a test on that, spinning the rotors up to 2,800 RPM, and Ingenuity handled the extra stresses and power draw well. A 14th flight is planned to see how well the rotors bite into the rarefied air, but Ingenuity’s days as a scout for Perseverance could be numbered.

If you thought privacy concerns and government backdoors into encryption technology were 21st-century problems, think again. IEEE Spectrum has a story about “The Scandalous History of the Last Rotor Cipher Machine,” and it’s a great read — almost like a Tom Clancy novel. The story will appeal to crypto — not cryptocurrency — fans, especially those fascinated by Enigma machines, because it revolves around a Swiss rotor cipher machine called the HX-63, which was essentially a refinement of the original Enigma technology. With the equivalent of 2,000-bit encryption, it was considered unbreakable, and it was offered for sale to any and all — at least until the US National Security Agency sprung into action to persuade the inventor, Boris Hagelin, to shelve the HX-63 project in favor of electronic encryption. The NSA naturally helped Hagelin design this next generation of crypto machines, which of course all had backdoors built into them. While the cloak and dagger aspects of the story — including a possible assassination of Boris Hagelin’s son in 1970, when it became clear he wouldn’t “play ball” as his father had — are intriguing, the peek inside the HX-63, with its Swiss engineering, is the real treat.

One of the great things about the internet is how easy it is to quickly answer completely meaningless questions. For me, that usually involves looking up the lyrics of a song I just heard and finding out that, no, Robert Plant didn’t sing “Whoopie Cat” during Misty Mountain Hop. But it also let me answer a simple question the other day: what’s the largest single-piece metal object ever created? I figured it would have to be a casting of some sort, and likely something from the middle of the previous century. But as it turns out, the largest casting ever appears to have been manufactured in Sheffield, England in 2015. The company, Sheffield Forgemaster International, produced eleven castings for the offshore oil industry, each weighing in at over 320 tonnes. The scale of each piece is mind-boggling, and the technology that went into making them would be really interesting to learn about. And it goes without saying that my search was far from exhaustive; if you know of a single-piece metal part larger than 320 tonnes, I’ll be glad to stand corrected.

Have you heard about “teledriving” yet? On the face of it, a remote-controlled car where a qualified driver sits in an office somewhere watching video feeds from the car makes little sense. But as you dig into the details, the idea of remotely piloted cars starts to look like one of those “Why didn’t I think of that?” ideas. The company behind this is called Vay, and the idea is to remotely drive a ride-share vehicle to its next customer. Basically, when you hail a ride, a remote driver connects to an available car and drives it to your location. You get in and take over the controls to drive to your destination. When you arrive, another remote drive pilots the car to its next pickup. There are obvious problems to work out, but the idea is really the tacit admission that all things considered, humans are way better at driving than machines are, at least right now.