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BYOE: A Method for Creating CAD-based, Two-sided Molded Prototype Parts

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2017 ASEE Annual Conference & Exposition


Columbus, Ohio

Publication Date

June 24, 2017

Start Date

June 24, 2017

End Date

June 28, 2017

Conference Session

Division Experimentation & Lab-Oriented Studies - Bring Your Own Experiment

Tagged Division

Division Experimentation & Lab-Oriented Studies

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Paper Authors


Christopher P. Pung Grand Valley State University

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Dr. Pung has interests in experiential learning, design processes and student teams.

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Amanda E. Stark NASA Langley Research Center

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Amanda E. Stark received her Bachelor of Fine Art in Art and Design (2003) from Grand Valley State University and a Master of Fine Art (2006) from Bowling Green State in 3-Dimensional Art. Her art work has received numerous awards and has been added to some permanent collections. She has a Bachelor of Science in Engineering (2016) from Grand Valley State University. She is the recipient of the Wisner Engineering Scholarship (2015-2016) and two NASA NIFS Internships (2015). She is currently pursuing a Master of Science in Mechanical Engineering at Old Dominion University and has been awarded a Pathways Engineering Trainee Position at NASA Langley Research Center in Hampton, Virginia.

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Matthew Steven Dykstra

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Jill Morris

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BYOE: A method for creating CAD based two sided molded prototype parts

Abstract: At Grand Valley State University the advanced product design class requires several prototypes to be created over the course of the semester. Prototypes that accurately reflect the geometry produced using CAD software can be difficult. Two sided moldable parts have been particularly challenging to create in the past. Aluminum molds may cost several thousand dollars and take a significant amount of time. Manual methods suffer from the inability to consistently reproduce curved surfaces and other details. The students were tasked with refining and documenting an inexpensive process to create parts requiring a two sided mold that would accurately produce the geometry shown in a CAD model. CAD models for the molds were created using Solidworks employing the Mold Tools Add-In. A makerbot was utilized to print the mold halves. Excess material was trimmed from the mold halves and a release agent was applied to the internal surfaces. A mixture of cornstarch and silicone caulk was placed in the molds which were then clamped for twelve to 24 hours to allow the silicone to cure. The parts were then removed and trimmed. This paper will include the detailed instructions using Solidworks and its mold making package as well as a short DOE regarding the mixture of silicone and cornstarch. The author will be able to bring the materials to a talk for a brief demonstration. I will likely have a better title as well.

Pung, C. P., & Stark, A. E., & Dykstra, M. S., & Morris, J. (2017, June), BYOE: A Method for Creating CAD-based, Two-sided Molded Prototype Parts Paper presented at 2017 ASEE Annual Conference & Exposition, Columbus, Ohio. 10.18260/1-2--27994

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