Corian Molds

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samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Corian Molds

Post by samc99us » Tue May 26, 2015 6:14 pm

Figured I would post this here, they haven't even made it on to the model airplane site (rcgroups) I usually post to.

This is the bottom mold for a hand launch glider wing, cut on my fairly modified Shapeoko 2. The mold design was done in Solidworks, toolpathing in Mecsoft VisualMill 2012, g-code generated for LinuxCNC with G64 enabled.

A horizontal roughing cut was done at 80IPM with a 0.25in, 0.060 corner radius end mill from lakeshore carbide (where I buy all my tools). The DNP611 was set to 3.5 on the speed controller. Stepover was 50% with a 0.055" step down, and stock remaining set to 0.02". Finishing was done at 120IPM with a 0.125in ball nose mill, 15% stepover. A leading edge curve following cleanup path was run with the same 1/8" ball mill and an 8% stepover. Total cut time was roughly 4 hours. This is by far the highest quality part I have cut on my machine, and is notably superior to corian molds I have in my possession that were cut on an older Joes 4x4 machine.

I'm sure people want to know what upgrades made the largest difference in overall machine cut quality. For me, the absolute biggest improvement was installation of a custom ACME anti-backlash nut. That made a HUGE difference in the finish quality of the part. The other upgrade that certainly helps is a 40 x 60 x-axis gantry (stiffer) and my ACME z-axis w/ belt drive kit which lets me achieve 130IPM on the z-axis with some pretty high acceleations (I believe in the 30 in/s^2 range). This is a big deal since my z-axis can keep up with the rest of the machine and I can actually see cut speeds of 120IPM when milling.
Attachments
tip_small.jpg
tip_small.jpg (118.54 KiB) Viewed 1767 times
mold_overview_small.jpg
mold_overview_small.jpg (133.08 KiB) Viewed 1767 times
moldoverview_1_small.jpg
moldoverview_1_small.jpg (145.83 KiB) Viewed 1767 times
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

graycon
Posts: 13
Joined: Tue Feb 11, 2014 8:16 pm

Re: Corian Molds

Post by graycon » Wed May 27, 2015 4:39 pm

Looks nice! I'm curious how the wing itself turns out.

CastIrony
Posts: 650
Joined: Mon Jul 21, 2014 10:21 pm
Location: Portland, OR

Re: Corian Molds

Post by CastIrony » Wed May 27, 2015 5:48 pm

Cool! Do you sand the ridges down before casting?
Shapeoko 3 #192 - Complete! Needs limit switches.

Gadgetman!
Posts: 1061
Joined: Sun Aug 25, 2013 12:44 pm
Location: Norway
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Re: Corian Molds

Post by Gadgetman! » Wed May 27, 2015 6:42 pm

Nice!

Got any pictures of the glider?
(I just love RC gliders. Quiet, serene, and hours of fun. The fun part being the building process. Not that good a pilot... )
Weird guy...
Shapeoko 2014F: 1000mm X/Y, 300W Quiet Cut spindle, Arduino Uno/G-shield and GRBL 0.9i
15x30 drag chains, custom spindle mount, 9mm belts, 8mm endplates, 6mm motor plates.

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: Corian Molds

Post by samc99us » Wed Aug 05, 2015 5:23 pm

No casting. The cores is a piece of foam that gets squished in the mold.

And yes, all the ridges are sanded out and the corian molds made mirror smooth. We polish up to 2400 grit wet sandpaper then move into 3M polishing compounds. I think it's about $100 in material just to polish out a set of these wing molds.

Pictures of finished products are here: http://www.rcgroups.com/forums/showthread.php?t=1546707
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

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