2.

Rapid Tooling

2.1 Objective: To introduce and familiarize student with one of the prototyping
method for lab scale production
2.2 Lab Outcomes: At the end of the lab session, students should be able to
1. Explain in detail the functions, component and material involved in
the vacuum casting process.
2. Utilize the equipment for academic purpose.
2.3 Equipment: Vacuum chamber, Heating oven
2.4 Safety Instruction:
1. Avoid direct contact with the cured silicon rubber right after
curing process.
2. Use cotton glove when cut out the master part from the cured
mould.
3. Follow basic procedure when handling the sharp tools.
2.5 Lab Procedure:

2.5.1 Making of the Mould

1. Select the master part (the product that want to cast). Clean the and apply
silicon spray to the master part
2. Create a casting frame (for this lab, we will use box). Laminated the box using
cellophane tape to avoid the silicon rubber from stick to the casting wall.

3. Attached supporting bridge to the master part and the mould. The bridge will
act as runner during the casting process.

Bridge

Runner

4. Mix silicon rubber (mould) and the hardener (catalyst) with ratio of 2:1. The
amount of the consumables can be determine using the weighing scale which
depends on the volume of the casting frame. Pour the mixed chemicals into a
container.
5. De-gas the chemicals in the vacuum chamber. Pour the chemical into the
casting frame and de-gas again.
 6. Cure the silicon overnight at 40oC in oven.
7. After curing, remove the casting frame, runner and bridge from the hardened
mould.
8. Cut the mould into halves alongside the separating line (marked). Keep
cutting in wave-like.
9. Carefully remove the master part from the hardened mould.

2.5.2 Casting

1. Assemble and stick both halves of the mould using staple gun. Apply force
during the assembly process, to avoid gap.
2. Pour the resin (based from the weight of the master model) and the hardener
(catalyst), with ratio of 1:0.05 into a separate container.
3. Heat up the mould for 10 minutes at 40oC. Then, connect the mould to a
runner and hose in the vacuum chamber.
4. Pour the hardener into the resin container during de-gas in the vacuum
chamber. Stir the mix for 3 minutes and pour the mixed resin into the mould
slowly to avoid overflow on the mould.
5. Retrieve the mould carefully from the vacuum chamber and place it in the
oven for 15 minutes at 70oC.
6. Retrieve the mould from the oven. Remove the staples and cast part carefully
to avoid damage to the mould and cast part.
Name :

ID :

2.6 Project report: Rapid Tooling

A. Making of Mould
Function To form and produce the silicon rubber into the shape of the master
part.

Contents/ 1. The casting frame was created by using box and the box was
Activities
laminated using cellophane tape to avoid the silicon rubber from
sticking to the casting wall.
2. The supporting bridge was attached to the master part and the
mould as it will act as runner during the casting process.
3. The silicon rubber (XTX 45) and the hardener (XTX 45 dry) was
mixed with the ratio of 2:1. The weight of silicon rubber and the
hardener was determined using the weighing scale which
depends on the volume of the casting frame. Based on the
volume of the casting frame, 614g of silicon rubber and 307g of
hardener was used to make the mould.
4. After weighing, the chemicals were undergone de-gas process in
the vacuum chamber to remove any trapped air. Then, the
chemicals were mixed into a container.
5. The mixed chemicals undergo de-gas process again after mixing
in the container. Then, the chemicals were poured into a casting
frame (laminated box) and the de-gas process was repeated
until there was no gas in the mixture.
6. The silicon was left to cure overnight at 40oC in oven.
7. After curing process, the casting frame, runner and bridge were
removed from the hardened mould.
8. The mould was cut into halves in wave-like pattern alongside the
separating line. The wave-like pattern will avoid misalignment
during casting
9. The master part was removed carefully from the hardened
mould.
10. Figure 1 shows the hardened mould that was done during the lab
session.

Figure 1: Hardened silicon rubber mould

B. Casting
Function To produce a small series of functional master parts from the mould

Contents/ 1. Both halves of the mould were assembled and sticked using a
Activities
staple gun. Force was applied during the assembly process to
avoid gap.
2. The resin and the hardener were poured with a ratio of 1:0.05
into a separate container.
3. The mould was heated up for 10 minutes at 40oC to reduce
thermal shock from rapid cooling. Then, the mould was
connected to a runner and a hose in the vacuum chamber.
4. The hardener was poured into the resin container during the de-
gas process in the vacuum chamber. Then, the mixture was
stirred for 3 minutes and then the mixture was poured slowly into
the mould to avoid overflow on the mould.
5. The mould was retrieved carefully from the vacuum chamber.
Then, the mould was placed in the oven for 15 minutes at the
temperature of 70oC.
6. The mould was retrieved from the oven. Then, the staples and
the cast part were removed carefully to avoid damages towards
the mould and the cast part.
7. Figure 2 shows the cast part that was done during the lab
session.
8. The cast part has defects due to air trapped during casting.

Figure 2: Cast part

2.7: Questions

1. Explain the function of heating oven and vacuum chamber to the vacuum
casting process.
 Heating oven - to cure the silicon and resin.
 Vacuum chamber - to remove any trapped air.

2. Compare the difference between vacuum casting method and normal

casting method used in industry.
 Production for the vacuum casting has lower cost compared to normal
casting process.
 Vacuum casting can be used for small batches of high-quality prototypes or
low volume end use parts.
 The mould of normal casting can be used for longer time compared to
vacuum casting.
 Vacuum casting has lower development time compared to normal casting

3. List other type of rapid tooling existed and their functions in details.
 3D printing – Processes in which material is joined or solidified under
computed control to create a 3D object with material being added typically
layer by layer.
 Direct metal laser sintering - Used to create a plastic injection mold by fusing
together metal particles to make a solvent in a process called sintering.
 Sand casting - metal casting process characterized by using sand as the
mould material.

4. List and explain the advantages and disadvantages of vacuum casting

methods.
Advantages Disadvantages
High precision with fine detail The silicon mould has shorter
lifetime
Have lower cost of production Hard to obtain consistent wall
thickness
Can be used for small batches of Only one material can be formed at a
high-quality prototypes time