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3D print mold concrete


Desktop 3D Printed Mold Enables Delicate Concrete Furniture - 3DPrint.com

There are countless applications for products and parts made with 3D printed molds, such as prosthetic aligners, microneedles and organ-on-a-chip devices, and even building restoration. Experimental design studio Slicelab, remotely based out of Denver and New York, specializes in digital fabrication, and offers design services in architecture and product/furniture design. Founded in 2012 by Arthur Azoulai and Diego Taccioli, the studio says that it operates “between the disciplines of art and architecture,” and has recently been researching the use of 3D printing in fabricating molds for complex concrete forms. This work resulted in a truly lovely piece of furniture called the Delicate Density Table.

Slicelab was attracted to 3D printing for this project because the technology has fewer limitations in terms of cost and time to design and create complex forms.

“A concrete exploration using 3D printed molds with a goal to see how delicate, detailed, and finite concrete can get while still being structurally rigid,” the studio wrote. “Using 3D printing as a new way to realize concrete through its ability to make molds, we have been interested in pushing the concretes’ natural limitation through fine geometries.”

Slicelab’s co-founders Arthur Azoulai and Diego Taccioli sitting at the Delicate Density Table

Concrete features a very compressive strength, but is more brittle when it’s used to create shapes with fine geometries that create a lot of tension loads. Additionally, the material also has the unique ability to take on any shape, while 3D printing has the ability to create complex geometries, and Slicelab saw the potential in combining the two to create a piece of furniture that had both density in material and a delicate form, while still maintaining the strength of the concrete. The studio partnered with Concreteworks and Hummingbird 3D for this project, which resulted in multiple unique molds that were then put together and used to make an 86 kg white concrete table with 152.5 x 45.5 x 38 cm dimensions.

The studio figured out the overall structure of the model ahead of time, through the use of digital simulation and optimization. This is when they realized that, due to the size of the table design and the build volume constraints of the LulzBot TAZ 3D printers they would be using, they would need to break the model down into 23 separate pieces.

Each of the 23 parts were oriented and optimized in a certain order so the least amount of supports would have to be used, which would help speed up assembly. The pieces were 3D printed out of recycled PLA, and then fastened together to make a single 5 ft. investment mold, which weighed about 66 lbs and was able to hold up under 200 lbs of non-reinforced super high-performance concrete.

“The order of which the pieces were assembled played a huge roll in how well the pieces aggregated together,” Slicelab explained. “Even with absolute printing precision, the plastic can crack, warp and often create uneven surfaces that require a lot of post-process work to fully function as a watertight mold for concrete especially when put onto a vibration surface. ”

The team created the mold with a built-in, leveled diamond platform on top, so it could be positioned upside down and flat when the concrete was poured inside, to ensure that most air bubbles would be on the bottom of the table and not visible from the top. This reinforcing platform also helped to keep the center of gravity low during pouring, and was also designed to be the only part released from the concrete in a single piece. Speaking of pouring concrete, the voids at the bottom of the mold were used to pour concrete into three major access points, down through the ten legs, and into the main cavity of the bench.

Once the concrete had completely cured inside, the mold was literally broken off piece by piece to reveal the final Delicate Density Table. Slicelab then used diamond pad wet sanding to get a mirror-like finish, which also really emphasized the fluid form of the top of the table—a major contrast to the porous texturing on the table legs.

Since we’re all about sustainability here in the AM industry, it’s nice to know that the team also saved as many of the broken pieces of the mold as possible, so they can be used at a later date for a different project.

(Source/Images: Slicelab)

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Tagged with: 3d printed furniture • 3d printed mold • 3d printed table • 3d printing molds • concrete • concrete furniture • design studio • Investment Molding • Lulzbot TAZ 3D printer • mold making • pla • Slicelab

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Printing molds for concrete - 3D Printing - Talk Manufacturing

aaronpaulsmith

#1

Hello

I’m looking at doing a few concrete home projects, i’ll like to get some molds printed that can be used to cast concrete and be re-used multiple times.

I would like the finish of the concrete casts to be smooth and potentially quite detailed, i’m looking at producing things like, pendants, vases, bowls, plates etc.

i’m guessing it should be some sort of rubber/silicone but not sure of the type of printers I should be looking for.

Preferably a printer in the london area would be best but happy to use any location really providing delivery is offered.

Thanks

5 Likes

metaobjects

#2

Hi Aaron, we’re based in London and able to create high detail RTV silicon molds. We’ve not tried casting concrete ourselves but we’ve read it works well https://www.youtube.com/watch?v=TYhOso98N_k

We can also supply 3D printed templates if you’d prefer to pour the silicon yourself.

What size molds are you looking to create?

aaronpaulsmith

#3

My model size is

The 3d model i have made is actually a mold and made of 3 pieces, you mention a template above what exactly do you mean by this, would that actually require me to model the actual object rather than the mold?

I uploaded my model to 3dhubs to today to get a idea of prices, i have either misjudged 3d printing costs or my model is incorrect getting prices in excess of €10000 does that seem right?

metaobjects

#4

The dimensions haven’t come through, if you can give a rough width / height / depth then I can tell you if it’ll be possible for us to print, as if it’s within our max. printable size then it’ll cost a lot less than that! We can supply silicon molds of the exact models you provide so don’t worry about having to adjust the model. Thanks, Andrew

aaronpaulsmith

#5

the object is around 25 cm high, 15 cm wide and deep, what would be the limits I should keep within to keep costs down?

metaobjects

#6

Yeah that’s likely too big for our printer as the largest single piece we can create is 16x12x12 cm, and even then the resin material we use is more expensive than FDM so large parts get expensive quickly.

It might be possible to optimise the mold, if you’re able to send the original shape to us then I can have a look at it and let you know how feasible it is

flowalistik

#7

Yesterday I talked with a friend about concrete casting, and today I see this post. Any info or progress please share it!

I know Vangrei, tthey do concrete objects, but I don’t know if they cast it using 3D printers in the process or if it’s just a different method.

aaronpaulsmith

#8

Hi andrew, been busy ilk try and get that model to you later in the week. Thanks

Gaffanon

#9

Having cast concrete while silicone molds are great they are expensive you might want to consider a Urethane mold rubber instead less cost and some are made with mold release in the rubber already such as Renyolds Reoflex 30 or 40 wet. they will last a very long time and at a third the cost of silicone

aaronpaulsmith

#10

Thanks for the tip

Development and production of molds for concrete in Ukraine - KLONA

3D modeling technologies

3D modeling technologies have dramatically improved the process of creating molds. If earlier there were difficulties with the elaboration of small details and patterns, now it is easy to implement any, even non-standard idea of ​​a mold for concrete.

Molding tools may have different requirements, but the 3D mold will convey the smallest details with high precision. High-quality molds provide mass production of products of any complexity:

  • paving slabs;
  • figured articles;
  • flowerpots;
  • columns;
  • interior items;
  • decorative panels.

KLONA offers comprehensive mold making services from 3D modeling to small and large batch production in Ukraine and Russia.

Scope of molds for press concrete

Molds for press concrete (stamped concrete) are needed for the manufacture of concrete surfaces. The technology is especially popular when creating decorative finishes:

  • facades of houses;
  • internal walls;
  • fences;
  • garden paths;
  • interior elements (fireplaces, stairs, columns, arches).

Depending on the stamp, concrete takes on the shape and relief of natural stone, wood or any other surface. With the help of molds for 3D panels, it is easy to imitate tiled masonry, paving stones or mosaics.

You can also create a 3D effect on the wall, giving the interior an unusual look

Stages of manufacturing a mold for decorative concrete

Terms of reference

When forming the terms of reference for manufacturing molds, the format of the future product, its shape and features of the products for which molding equipment is being developed are taken into account.

Product design development

Mold design includes parameters that will provide the necessary technological characteristics of products.

3D model of mold

Before making a mold, KLONA industrial designer creates its 3D model. To do this, we use photographs, sketches, drawings, technical documentation and other information that helps in creating a realistic model. You can also make copies of finished products, creating their 3D model.

Prototyping

Mold prototype can be 3D printed or made from solid plastic (depending on size and project timeline). Prototyping allows you to evaluate the functionality of the mold, check its performance and make the necessary changes, if necessary. The prototype is being tested for quality and compliance with the terms of reference. If required, the mold is polished, the surface is given relief, pattern, gloss or, conversely, dullness.

Launch into production

A successful mold prototype (that has been initially produced and has been reworked) is launched into production. At this stage, the required number of molds that are required for the manufacture of concrete products is calculated.

The choice of material is influenced by the quality requirements of the finished products and the scale of production.

TELL US ABOUT YOUR PROJECT!

Buy molds for press concrete to order

KLONA offers the production of molds for stamped concrete from polyurethane and plastic:

  • Plastic molds are a budget solution for starting a business or for small-scale production of concrete products. When used correctly, the molds are dimensionally stable and resistant to wear over a long period (200-500 production cycles).
  • Polyurethane molds - durable, designed for mass production. They are highly flexible and tear resistant. They perfectly convey the shape of the relief to the concrete impression.

The materials have low adhesion to concrete, so the products are easily separated from the mold, facilitating the production process. Dense decorative 3D stamps for concrete clearly convey the pattern and relief. Our technical equipment allows us to produce standard and design molds: with any relief, non-standard sizes and shapes.

The price of molds for concrete to order

The cost of manufacturing a mold depends on several factors:

  • complexity of the process;
  • product material;
  • the size and shape of the product;
  • product geometry features;
  • terms of project implementation;
  • manufacturing lot size.

The timing of the project, the material and the volume of batches are the key points in determining the price of manufacturing molds.

Quick budget option - silicone molds. Their resource is limited to a few production cycles, but production can be started faster.

More expensive, requiring detailed design and a long manufacturing process - polyurethane molds that have no life limit (if used correctly).

The minimum mold production time is 3 months.

Benefits: why you should order molds for concrete from KLONA

  • production of molds on high-precision equipment;
  • high quality of the pattern and pattern transferred to the product;
  • quality control of materials used for the manufacture of molds;
  • variety of projections, shapes and designs;
  • the possibility of making any number of 3D-forms;
  • the ability to realize complex sizes and geometry of molds.

Entrust your production tasks to the specialists of KLONA. We are able to develop and put into production original molds for concrete of any complexity!

How to 3D Print Injection Molds, Castings and Thermoforming Molds

Injection Mold Making is used in various industries by professionals such as designers, manufacturers and educators to create short production runs, prototype complex molds , testing of plastic products for further use in practice and, mainly, in cases where it is necessary to make several copies of a part without much cost and effort. This allows you to quickly produce small batches of 150 to 600 parts, or to check the design of the mold before proceeding to the manufacture of expensive tooling.

Desktop 3D printing allows engineers and designers to expand their 3D printer's material usage and capabilities beyond rapid prototyping into industrial manufacturing. 3D printed models for molding processes are generally faster and cheaper than CNC milled models and easier than silicone molds.

Small batch 3D printed molds are generally less expensive and easier to make than CNC or silicone molds.

In this article, we will look at three mold making technologies that are easily complemented by 3D printing: injection molding, casting, and thermoforming. For an in-depth look at these technologies, as well as tips on mold making and 3D printing, see our latest webinar.

Watch the webinar now

Injection molding was invented in 1872 by John Wesley Hyatt and initially worked on the same principle as a hypodermic syringe. The state-of-the-art injection molding plant was finally completed in 1956 as a result of the invention of the floating auger.

In a modern injection molding process, a floating screw feeds plastic resin pellets from a feed hopper into a heated extruder barrel. As they approach the heater, the pellets melt and are pushed into the pressurized mold cavity. After molding and cooling of the part inside the mold, it is ejected and the mold is reused.

Small plastic part made with an injection mold 3D printed directly from Formlabs High Temp Resin.

The polymers used for injection molding processes are relatively cheap and can be used to achieve a wide variety of properties, so injection molding is widely used to create packaging and consumer goods (fun fact: LEGO elements, where both strength and durability are important). precision, manufactured by injection molding).

With affordable desktop 3D printers, heat-resistant 3D printing materials and injection molding machines, you can create your own molds to produce functional prototypes and small plastic parts. In the case of low-volume production (approximately 10-100 parts), 3D-printed injection molds save time and money compared to expensive metal molds. They also provide a more flexible approach to manufacturing, allowing engineers and designers to create mold prototypes and test mold configurations or easily modify molds while continuing to work on their projects at little time and money.

Forms can be directly 3D printed using a variety of materials such as standard or High Temp Resin Formlabs. The tests for our Injection Molding Technical Report were conducted using a Galomb Model-B100 Injection Molder, which cost about $3,500.

Technical report

Download our white paper for a step-by-step description of the methods used to test the performance of 3D printed injection molds, as well as best practices and best practices for 3D printing mold design.

Download white paper

Casting is a popular technology in many industries such as jewelry, dentistry and mechanical engineering. It can be used for the manufacture of both small and large parts from a wide variety of metals. Invented over 5,000 years ago, casting allows for a wide variety of materials and is one of the easiest ways to make metal parts.

Casting creates an empty mold from a master mold, which can be handmade or 3D printed (as shown in the BJB Enterprises video tutorial on how to make a silicone mold with a Formlabs SLA 3D printer). The master mold is immersed in the mold material such as sand, clay, concrete, epoxy, gypsum or silicone. The mold material solidifies, plastic or metal is poured into the mold, and the master mold is either removed or burned to form the finished part.

You can print an accurate casting master mold using. for example, Formlabs Castable Resin, which burns to form a reusable mold.

Technical report

In this white paper, you will learn how to cast jewelry designs from 3D models and how direct lost wax or wax casting works as a mold making method.

Download white paper

Vulcanized rubber castings can be used to make wax models in quantities required for investment casting of metal parts such as jewelry, small industrial parts and toys.

3D printers can produce master models that are used to mold room temperature vulcanized (RTV) castings and even heat resistant vulcanized rubber castings.

Directly 3D printed jewelry samples can be used to make room temperature vulcanized (RTV) rubber or high temperature vulcanized natural rubber molds.

In design and production, the production of metal castings is the most economical and productive process for manufacturing parts with small features and complex geometries. Manufacturers and designers use casting to make critical parts in the aviation, automotive and healthcare industries.

Stereolithographic 3D printers (SLA) are ideal for casting processes in the manufacture of metal parts with less cost, greater design flexibility and in less time than traditional methods, without the costs associated with direct metal 3D printers.

Technical report

In this white paper, you'll learn how you can use the speed and flexibility of 3D printing without the cost of direct sintering metal printers, using metal casting workflows and detailed step-by-step sand casting tutorials; Learn about investing in molding processes using Formlabs 3D printers and resins.

Download white paper

These two processes, thermoforming and vacuum forming, are similar to injection molding in that they use heat and pressure to create finished plastic products. These techniques were developed in the 1940s to produce flawless aircraft cockpit lights and embossed army maps.

Today they are commonly used in automotive parts packaging where dimensional accuracy may not be as critical and thickness variation is acceptable.

The packaging for this razor was vacuum formed.

In thermoforming, a heated sheet of plastic is pressed between two mold halves to form a part. Vacuum forming uses only one half of the mold, and vacuum is used to press the plastic against the mold. The installations used in these technological processes are very cheap, they can even be made by hand.

In this diagram, A represents the pressure on the back of the mold, B is the pressure from the plastic being applied to the mold, and C represents the heat of the plastic itself.

Learn more