In this project we aim to cast a box consisting of 2 materials: a hard inside to keep electronics in place, and a soft outside to make it shock proof.
First we will cast the epoxy inside of the box, using 2 molds. Then we cast an extra layer of vitaflex rubber on top for the soft outside. For the whole process the laser cutter and the shopbot are needed, and the toolset for moulding and casting.The process consists of the following steps:
1. design of the moulds in Rhino: one mould for the core; one for the epoxy shape; one for the vitaflex layer
2. making boxes for the wax
3. melting and casting the wax
4. milling the positive shapes with the shopbot
5. casting silicone to get negative shapes (the moulds)
6. casting the epoxy, using the first two moulds
7. casting the vitaflex, using the first and third mould
In the documentation sections each step is described.
