Sand Casting
Our sand casting lab in the materials and manufacturing class was particularly engaging. We used a bismuth-tin alloy due to its significantly lower melting point, making it easier to handle compared to other metals. Through this process, we learned to identify common sand casting defects like gas porosity and misruns, which are visible in the attached picture.
This lab provided a unique metalworking experience and was a change of pace from the usual techniques I’m accustomed to in Bray Lab.
Sheet metal box
This project provided valuable practice with various sheet metal working tools, including the 3-in-1 bender, table bender, hole punch, rivet gun, and English wheel.
The most interesting part was experiencing firsthand how the raised middle of the box significantly increased its stiffness. This design feature adds resistance to deformation by creating structural rigidity, as it distributes stress through the crystalline structure of the metal.
Injection molding
Worked with the Model 25 table-top injection molder to produce polypropylene dog-bone specimens for tensile testing. The process involved melting polypropylene pellets at up to 200°C and injecting the material into pre-machined aluminum molds. I adjusted the injection force to balance filling the mold completely while avoiding over-pressurizing the sample.
Through this project, I learned the basics of injection molding, including mold features like sprues, runners, and ejector pins, and gained hands-on experience with polymer processing and troubleshooting.
Acrylic Phone Stand
Used a 600D Hot Wire Strip Heater to shape laser-cut acrylic into a functional phone stand. The process involved heating the thermoplastic along pre-determined lines using adjustable hot wires to ensure precise and even bends. Once softened, the acrylic was bent into shape and allowed to cool, creating the design pictured.
This project introduced me to thermoplastic forming techniques and provided an interesting way to turn 2D laser cuts into 3D parts!
Skills & Knowledge Developed
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Skills & Knowledge Developed 〰️
Sand casting
Anatomy of a sand casting setup
3-in-1 bender
Table bender
Riveting
English wheel
Sheet metal working
Polymer fabrication
Process troubleshooting
Strip heating
Technical craftsmanship