Introduction

For our final project, Madison and I decided to make our chess pieces in the shape of squirrels. We had very little experience with VCarve, the CNC machine, and molding and casting, so this was definitely an interesting learning experience.

Process 

We began by downloading a squirrel chess piece in Thingiverse to Meshmixer to split it in half. Then we downloaded the file to SolidWorks to add the base component. After saving the file we 3D printed it. Then, we realized that we needed the other side of the squirrel for the other piece so we went back to Meshmixer to get the other half. We used Solidworks to create the mirroring positive base for the squirrel. To create a physical copy of the other side of the mold we used the Shapeoko, but first we created toolpaths in VCarve. We made a roughing pass using a ¼ inch bit and a finishing pass using a ⅛ inch bit. The CNC base and 3D printed base are shown below.

Next we created the molds. First we created boxes of indeterminate size around the bases using hot glue and duct tape to hold it together. Then we made the silicone by mixing equal portions of the yellow and blue solutions by weight. We poured the liquid to one centimeter above the top of the base. After leaving the mold overnight we removed the cardboard and cut off any excess mold using an Xacto blade. Both molds are shown below.

To make the chess pieces we put the molds together and secured them with rubber bands. We then made a mixture of liquid plastic and poured it into the mold pocket as shown below.

After making two white squirrels we used the dyes to produce different color squirrels. After they set we finished the squirrels with an xacto blade and sandpaper. The final product is pictured below.

 

Reflection

This project involved many new softwares and processes, so we learned a lot over the last few weeks. There were some challenges setting up the files in Vcarve (specifically, figuring out how to make our cut take less than 9 hours) and with the CNC machine itself (having to learn how to use the Shapeoko when the Nomad broke), but these presented many opportunities to learn and develop new skills. We really enjoyed the process, and felt that our hard work paid off when we saw the final product, which was actually very fun to make!

Cost Analysis

3D printed mold: $1.50

Wood for CNC: $3.25

Materials for silicone mold: ~$15

Liquid plastic: ~$10

TOTAL: $29.75