Step 1: Overview
Fast forward one month later to Instructables' new diggs at Pier 9 nearing completion and the last two weeks of my Artist in Residency quickly closing in. I had the green light from NoahW to get creative with the newly relocated armada of Objet Connex 3d printers. I was excited to finally use these crazy machines, but still wasn't sure how I would approach the material issues that I had learned about during my visit with Steve.
I love making things that are seen and touched on a regular basis; useful things inspired by everyday life. With the toxicity and visceral quality of 3d printed materials hindering my thought process, I spoke to Randofo (friendly and helpful featured author at Instructables) about utilizing the good characteristics of 3d printing while avoiding the bad ones. He suggested I create molds. What a great idea! Making molds would allow me utilize the precision of CAD software and 3d printing while fabricating the final product(s) in a secondary material. I immediately recalled my recent desire to make small scale concrete castings...
*Photo credit: audreyobscura
Step 2: What You'll Need
That being said, here's what you'll need:
• Free CAD Software Application like Autodesk 123d Design or Autodesk Inventor Fusion
• Objet Connex 3d Printer w/ Vero and Tengo Resins
• Casting materials:
a. Duracal gypsum mix
b. 2 Medium sized buckets
c. 2 Putty knives or trowels
d. A mixing stick OR a hand drill mixer contraption
e. Mold release
f. Dust mask
Step 3: Ideation
Step 4: Using CAD to Model Your Object
Though I explained earlier that this instructable is not meant to inform the creation of any one specific design, I felt that including imagery of my cord weight build process would be useful to those who were new to CAD modeling. An important note to keep in mind here is that there are always multiple routes you can take to model an object. Knowing which method to use comes down to a combination of preference and your understanding of the toolsets. I tend to envision objects through an orthographic lens, so I prefer to shape my models through the use of two-dimensional sketches.
*Thanks to fellow Artist in Residence M.C. Langer for allowing me to hijack his work computer to make this Instructable!
Step 5: Creating a Mold From Your Object
Step 6: Printing a Flexible Mold
Step 7: Casting
A great resource if you're new to concrete: