toy robot project

thingiverse

To display various processes paired with 3D printing technologies, I created a DIY factory for higher volume home manufacturing using a project as an example. However, the final part wasn't too complex and had been used in other technical projects. A friend requested small plastic toys of his company logo for promotional purposes, which required more than just 3D printing but not enough to warrant traditional manufacturing. To begin, I created a 3D file of the logo in Solidworks and printed parts for size reference. Once the scale was decided, I used high-resolution 3D printing to create a test mold - a simple negative cavity made from the original 3D file. This step ensured that the final cast part would be durable and free of casting problems. Next, I employed a desktop Roland MDX-20 mill to cut a wax positive for casting by assembling multiple parts of the original design on a uniform ground plane. After cleaning up some edges, I boxed in the part with plexi for casting purposes. Multiple molds were pulled from the original positive to cast dozens of parts at once. For mold making, Smooth-On Oomoo silicone was used, as it is easy to use for simple designs. The final parts were cast using Smooth-On Smooth Cast resin and compatible pigments. To ensure a clean process, I added extra resin to the molds and forced excess into channels designed in the mold with a squeegee. The resin set up within minutes, allowing the parts to pop out like ice cubes from a tray.