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10.08 3D Print Slipcast Mold Shells 3D Model Assignment

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Assignment Deliverables

  1. 3D model file of prepared mold pieces, divided and shelled (.blend, .f3d, .ma, .mb)
    • Label file YYYYMMDD Lastname Firstname prepared mold model file
  2. Exported OBJs or STLs of prepared mold pieces ready for 3D Printing (.obj, .stl, 3mf)
    • Label files YYYYMMDD Lastname Firstname mold piece for 3D printing

Assignment Overview

Use 3D modeling tools to identify undercuts, simplify undercuts, create parting lines, and ultimately make hollow forms for 3D printing to cast plaster inside to make a multipart slip cast mold.

Blender works better than Fusion 360 for high poly meshes. Although Fusion 360 has parametric features, for this application, Blender is likely the better choice. The complete process can be done in Blender and the mesh can be kept high poly. There is no need to reduce polygons with instant meshes if using Blender but it is ok to if desired.

Process

  1. Install the 3D Print Toolkit Blender Addon to assist with the detection and removal of undercuts, and scaling the bounds of your model.
  2. Use a combination of sculpting tools in Blender and the 3D Print Toolkit to remove undercuts .
  3. Use the 3D Print Toolkit to scale the bounds of you model external link to ~7-8 inches so it fits in the 3D printer.
  4. Add parting lines to separate mold into multiple parts. You can add parting lines in Blender or add parting lines in Fusion 360 .
  5. Create a mesh to be the form of your mold. This can be a cube but can also be a more contoured shape related to your model.
  6. Cut the parts of the mold along the parting lines. Cut the model away first, then subtract the parting lines.
    • Use the Boolean Modifier in Blender.
    • Use Modify > Combine in Fusion 360
  7. Hollow out the mold to make a negative space for the plaster to fill. Thickness of the walls should be ~1.6 mm - 2.0mm or a multiple of the diameter of the 3D Printer nozzle, often 0.4mm.
    • Use the Solidify Modifier in Blender. First remove the top and bottom of the mold piece to make a tube like structure, then solidify it.
    • Use Modify > Shell in Fusion 360. After shelling, use the Extrude tool to remove the bottom part of the mold to make it a hollow tube.
  8. Save your 3D modeling file from Blender or Fusion 360.
  9. Export each part of the mold. Label the parts.

Assignment Resources

Tutorial Video for removing undercuts in progress