How to create mold from a dynamic design?

[lordanubis]

Dear All,

My first post here, and not 100% familiar with the design terms, so please bear with me.
About my issue, that I can't solve is as follows.
As an example here I have a simple design of a plug, and I want to make a mold for it. Have done this before and it worked well.
The current design is however dynamic - meaning, some values can be entered in the variables table and this determines the size and shape of the design. The end design is a little more complex, but lets start simple, right 😉

Now I want to create a mold that is created dynamically on the basis of the entered data of the design.
I like to have some mold area's sliced dynamically, like at half way of the thickness of the plug, and others I should slice them manually. One part of the question is; how can I slice the mold at the top of the lower thickened part ( see construction line in the supplied sample file ). So far as I did before I need a mold of 4 parts; top, middle, bottom and a spindle. The product will be reasonable flexible.

My question, is there a tutorial available, or at least what are the right search terms for this? Or a step-by-step plan? How how should I start? The issue is, I need to get the design 3Dprinted as a show and test sample and as well of course the mold parts 3dprinted.

Any info or direction is very welcome. Thank you.

[wersy]

Do you mean something like this?

BTW, this is my first mold 🙂

 PS
and of course something to lock.

As you see, I am a beginner...
I hope to see a professional design soon 🙂

[lordanubis]

@wersy Hi Thank you for your reaction and for your design. It comes close.

But can you tell me how to do the combine etc?

I will try to have the cut line of the mold equal to the drawed construction line.

[jhackney1972]

I have created a Screencast of my method of creating this mold.  I had a little confusion, on my part, in the video and I hope you can get around it.  I did not make the outside dimensions of the mold parametric but I did the core.  You may have to make these dimensions parametric if your changes to the pattern body get to large.  I took the opportunity to fully constrain your first sketch but could not do so on the second one due to the way you had your parameters applied, I think I would consider a different way in the future.  Model is attached so you can take a look at it as the Screencast plays.  I will emphasis, the order of combine and visibility of bodies is very important.  I had to do it twice so I know it can be confusing.

[wersy]

There are many ways to create the mold.
The video of @jhackney1972  is a good example.

It is quite enough to divide the plug into two parts.
A tongue and groove connection is recommended for locking.

The tongue must have an offset of - 0.15 mm inside and outside. I would reduce the height by 2 layer heights.
In order for the plug to fit into the mold, either the mold or the plug must also have a negative offset of 0.15 mm.

My recommendation for printing:
extrusion width 0.5 mm
layer height 0.2 mm
2 perimeter
25% infill

[lordanubis]

@wersy 

@jhackney1972 

Wow beautiful. Speechless.

A little background, I did make some molds in SketchUp and some minor stuff in F360, but you can say I'm still new and so I appreciate what you both have made. I'm going to find out how you did it and try to copy it for a few different designs. Will also find out the functional steps and their purpose.

@wersy Splitting the design is not applicable here, because it has to be printed in one piece in a certain stiffness thermoplastic polyurethanes as a test product to test fit. Then I can order a product with the right stiffness to fill the mold.
But I know the trick, to avoid unnecessary support damage

There's only one annoying thing, and did read about this that it sometimes happens in Fusion360, is that the dimensions (D) aren't always visible whether I'm in 'edit sketch' mode or not.

I'm going to study it and come back to this. Thanks again.

BTW, I did order a book and found the Lars Live Serie's. Other good serie suggestions? I know youtube has a lot about F360 but like to find some series which are really in dept.

[TheCADWhisperer]

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@lordanubis wrote:

@wersy 

@jhackney1972 

There's only one annoying thing, and did read about this that it sometimes happens in Fusion360, is that the dimensions (D) aren't always visible whether I'm in 'edit sketch' mode or not.

I'm going to study it and come back to this. 

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Hover for a bit and the d variable should appear...

...or

you can always go to Parameters...

...and see your list of variables.

...and better yet...

name them yourself and then you don't have to search.