Week7
Molding and CastingCloning my bike key
I’m always using my bike to commute. And one day, I thought, what if I lose all the keys of the bike lock? So I decided to clone my bike key.
![](https://freight.cargo.site/t/original/i/d875364a0f9471c6af728417a56875048e2195668ed99ec628a65efc73ad80e0/IMG_6694.jpeg)
![](https://freight.cargo.site/t/original/i/9d8a5bc7160cd4a18ffb7e1c12960335850f2fe4104d811da03bfe9e9053a8a0/IMG_6687.jpeg)
(yes, it’s foldable!)
So here’s the plan.
Original Plan: 3D scan the key -> Put the data into CAD program -> Mill the mold of the mold -> Cast the mold -> Cast the Key
Revised Plan: 3D modle the key -> Put the data into CAD program -> Mill the mold of the mold -> Cast the mold -> Cast the Key
Process - I tried to 3D scan it first, and it was a total failure
![](https://freight.cargo.site/t/original/i/0cae01548da0bb3dbe8c37254300e9a0c035cd052a4dc2172fe3aae31d6b344a/IMG_1079.jpeg)
![](https://freight.cargo.site/t/original/i/c5b04df69b619a191a1e9a6bb5d81855d1a19dd5c1afee11930bc697ef59aea2/IMG_1083.jpeg)
It turns out even that level of reflection on the surface of metal part of the key - is critical to 3D scanner.
So I had only one choice - to 3D model it.
Process - A. 3D model the mold of the key
But the problem is - How can I scan the shape exactly? First I tried to use a scanner (not 3D, a 2D paper scanner), but I found a vise! so I put the key on the bottom and took pictrue of it while putting the phone on a perfectly horizental surface above the key. Below is the result.
![](https://freight.cargo.site/t/original/i/b20706e04a6a8fdf8179ec807f2bdeed92a020200cb24334fe0eb67d289cc125/IMG_1084.jpeg)
And put that into a CAD program. I used calipers to make sure the dimensions of the digital footprint is same with the physical one.
![](https://freight.cargo.site/t/original/i/12bd0f24ec13368f7ae25bb07022d3edba5aaee579b40d86e184b5aaa927a43c/Screenshot-2023-11-01-at-7.50.14-PM.png)
3D model the key, and boolean the key from the mold - you can see the mistake I made - actually I was following the instruction of one of the TAs ; ) but that’s how you learn. I did not realize what’s wrong before trying to put oomoo in the mold.
![](https://freight.cargo.site/t/original/i/b0ec78eb5f7c3d78f5dce8514447281983f54101d17f689f964146f560f93f7c/Screenshot-2023-11-21-at-3.59.16-PM.png)
Process - B. Mill the mold of the mold
When I’m ready with the 3D file, I turned on the computer linked to the CNC.
![](https://freight.cargo.site/t/original/i/2cf61a78cd4f21a05d7645b99a5290df513de3fd20cca7ea720a6ebbca9c65c6/IMG_1086.jpeg)
![](https://freight.cargo.site/t/original/i/5ae5e7fa430d6f507b0c54df204b960fd06e9c75e63205d08bf29fdf772c13b7/IMG_1087.jpeg)
I
By using mods, I co
![](https://freight.cargo.site/t/original/i/45156bc44c75bf667c07c0e67d7e7538ea5551b341b1ebb60a3c587bde5cce0e/IMG_1091.jpeg)
![](https://freight.cargo.site/t/original/i/9aba5d06016c4e4d9a67a0e517fa3aa699efd191b342a663e47ce58d9a4be336/IMG_1097.jpeg)
I had to remember the setting - matching the right endmill size and diemnsions.
After then. I could get the below in the preivew for the second cut (3D).
![](https://freight.cargo.site/t/original/i/3e0cb2f2b9c85b6c496e9f04b12def1331ef26d069454ee6b4485b44dfe77959/Screenshot-2023-11-21-at-4.11.45-PM.png)
By using double-sided tapes, we can attach a block of wax easliy on the bed surface.
![](https://freight.cargo.site/t/original/i/53b9ba0db49719adfcf4f1bde1863d241c367ac614f988f54bcd1cd9c11b3b4e/IMG_1103.jpeg)
![](https://freight.cargo.site/t/original/i/0cb8977605c0a9919623646dcaf926603204957c148af85653dc3ff528060b80/IMG_1106.jpeg)
When the file and wax were ready, I had to make sure it has a right origin position.
![](https://freight.cargo.site/t/original/i/fe0c829028a25dbf7ae2a1711c76df21c982480b58655fdf4ffaa93b6a501267/Screenshot-2023-11-21-at-4.28.14-PM.png)
![](https://freight.cargo.site/t/original/i/4c3ed03b4f0f2e14346d98368b82528ec82fb39e8d6dd688ea47a4dd75550fee/Screenshot-2023-11-21-at-4.31.13-PM.png)
When the endmill is at the right origin, the endmill needs to be adjusted in Z axis so that it touches the surface of the wax.
![](https://freight.cargo.site/t/original/i/1cb840d06580bbf1e51b938d7b09d1351d1c4b87ff8a29c5085a6ce4d6ac87a8/Screenshot-2023-11-21-at-4.16.21-PM.png)
![](https://freight.cargo.site/t/original/i/54a3b87d570d525fe35d57cb820ae8831ae7b9966229ef82f3a1bacc9ab630a7/Screenshot-2023-11-21-at-4.16.45-PM.png)
Then, starts milling for the first half! It’s important to vacuum after the milling is done to make sure the next milling is not disturbed by the debris.
![](https://freight.cargo.site/t/original/i/075f90eed8ebfc474c7545058178a9b56d8de271e1a9a42b70c4772b56dbb594/IMG_1109.jpeg)
![](https://freight.cargo.site/t/original/i/0fa141e4e92a49e44edfaccbb1318afbb31ea10921a632a1b7409b8439127d4c/IMG_1125.jpeg)
I had to change the endmil to 1/64 for the 3D milling, which is the second half of the whole process.
![](https://freight.cargo.site/t/original/i/986a9f5b5b43960576eddef41dd55df8f41fbb0f27d3588fb72d40cb9d2b6ffd/Screenshot-2023-11-21-at-4.37.23-PM.png)
![](https://freight.cargo.site/t/original/i/ecc2f1878925608d514a9ad57a00346978ad972e488b522323343449974d4e97/IMG_1138.jpeg)
Again, after reviewing the preview, push the ‘send file’ button. It is important to ‘save’ the setting before sending the file to the machine!
![](https://freight.cargo.site/t/original/i/015a12966655be16fc1bee34217451913039aa14a1782443a6dcb85176a2ff3c/IMG_1146.jpeg)
The result was clean, but you’ll know what the problem of this mold is soon.
Process - C. Put the oomoo inside the mold of the mold
![](https://freight.cargo.site/t/original/i/c405519900dbbaebd2ce39e3b7483e4a50711e11b00dee52bbe51f6cc5f91815/IMG_1317.jpeg)
![](https://freight.cargo.site/t/original/i/6266c28dd4044252022bfbebac6b55db4c44ab83e2e33daedb110aac89fe8dcd/IMG_1336.jpeg)
![](https://freight.cargo.site/t/original/i/61166db7d88db9953276ee4fcde20fb9a3355f55b90615230ce06b189a7ba037/IMG_1337.jpeg)
After 1.5hours, I could take out the mold! However,,,,,
![](https://freight.cargo.site/t/original/i/3529f5da9eee00b63fb00264288b7f423d1fed84d90a54f2a2123ee287014a0b/IMG_1358.jpeg)
![](https://freight.cargo.site/t/original/i/15c9b84c312ffbafdf7a5118386d03e93069c916c64c4980f92c1b37dec835b4/Screenshot-2023-11-21-at-4.49.05-PM.png)
![](https://freight.cargo.site/t/original/i/e635c56bb2477c7bacac9f38125a3722e694f4cdd5c3a4c95eebb2f4b28719a0/Screenshot-2023-11-21-at-4.50.03-PM.png)
It never worked. As there are two horizontal holes facing each other, I could not put the material and hold it in the mold.
![](https://freight.cargo.site/t/original/i/efc600a189caf139017d12e03c83373626cc8afcdd62b29c3ddd57e4b3cf02d6/IMG_1366.jpeg)
![](https://freight.cargo.site/t/original/i/f28fda26b9ae644bea453d8c91542d1149a65f14cf21b647e74bb5e13ab5760d/IMG_1355.jpeg)
The result of trying casting the half of the key. Julia’s sktech to explain how molding and casting works...
Thanks Julia!
So based on what I’ve learned, I re 3D modeled the mold of the mold.
![](https://freight.cargo.site/t/original/i/1e1000e54ef4a7a713b8d8177af1734ecaf98399122fd9a04052b806cbf1e4d6/IMG_1369.jpeg)
![](https://freight.cargo.site/t/original/i/1b03e5931a74cb0920d194f8f4f510df256dbfa8065b706944d2e654945cc690/IMG_1372.jpeg)
![](https://freight.cargo.site/t/original/i/f51859400e4d269c7c1422c474a45af858e664269e78a22bcf50e5cbab2d580c/IMG_1510.jpeg)
![](https://freight.cargo.site/t/original/i/44679092535ed9776c7e1fa580d8c12ff96f71c7b894f94c02133c2ae68f80cb/IMG_1641.jpeg)
![](https://freight.cargo.site/t/original/i/630df8c69f0a36e7fb5047b5656b313efdd2e8a567f0fbfa44aad94634658804/IMG_1643.jpeg)
![](https://freight.cargo.site/t/original/i/2d1c2734fc2f5e3109bfdce85358802547aa9ba2da509f4dfafc633a87d22ec3/IMG_1646.jpeg)
![](https://freight.cargo.site/t/original/i/41043e7dc72ea41e82385d4a3d4b6189edb580305e621d991b1fc1c17c66e0fb/IMG_1649.jpeg)
![](https://freight.cargo.site/t/original/i/355270ab5093006554ab31b0b4c962bfdd87afe575d0bf24ac96f7acc0afefb4/IMG_1935.jpeg)
Tried liquid plastic (325) and hydrostone
and also bismuth-tin alloy!
![](https://freight.cargo.site/t/original/i/83c019679d7ed7b32403f4da1bc4978e40d96946acde07e429d79be6235b0c65/IMG_1926.jpeg)
![](https://freight.cargo.site/t/original/i/88885db8b9a5739e63c7cf33883a7d5bd811beb189d132c0030a78c507e3cf57/IMG_1927.jpeg)
![](https://freight.cargo.site/t/original/i/21889b7d6acc48423b4532519f429fff296db830f45c71b1d8b27afe0369618b/Screenshot-2023-11-21-at-5.03.11-PM.png)
There is no swtich or whatsoever - so need to unplug it when not using!
![](https://freight.cargo.site/t/original/i/e445090f1b74c75630ddf0ac4c480faf88bdd24666b5dad66398d0776697028d/Screenshot-2023-11-21-at-5.02.25-PM.png)
putting some powders on the mold - not sure what the powders are!
![](https://freight.cargo.site/t/original/i/83633781d9ae3a0ede6d1e1069288ad4d0f9b2b28448346d104f1475b35351dd/IMG_1941.jpeg)
and making sure the two sides meet evenly! No more pressure than just kissing the surfaces
![](https://freight.cargo.site/t/original/i/965e1286ecdc8537186562bf943145d4db40b23fd34800a7f61c784f7c9d1658/Screenshot-2023-11-21-at-5.06.11-PM.png)
![](https://freight.cargo.site/t/original/i/9edd349f18f5e6ef851cc6310bafd250c51d5a3c6f4b02d7d1717265efec45dc/Screenshot-2023-11-21-at-5.06.36-PM.png)
It looks good!
Now it’s the moment of truth - I could not try this with hydrostone and plastic as they are too fragile or flexible.
![](https://freight.cargo.site/t/original/i/45ac1fff54750f647f1de1447c0e5d7ae017e4e6ec4fa1b8c0cd75f3defab93d/Screenshot-2023-11-21-at-5.07.14-PM.png)
But it did not work.
![](https://freight.cargo.site/t/original/i/e7c50a82e05fda79b09fefcd531e8f20041e324ee6b6599679e042c7b2f93d5c/IMG_2083.jpeg)
I think it did not work because of the thinkness of the key part - In that case, no matter how the cast comes out perfectly, It won’t work.
![](https://freight.cargo.site/t/original/i/5675da47f1832c157253ec804ae646699729544bc9c23b50b99ad1c53acf4c97/IMG_1965.jpeg)
I could not open the bike lock, but I learned a lot about casting and molding.
If I have time, I’ll try different metals and plastics with the fixed mold.