For the final project, we decided to make the Taipei 101 tower as the chess piece.
1. Design
My teammate, Lulu, is really determined to make Taipei 101, “this is my insistence,” she claims. Therefore, we agreed on what we wanted to make.
2. Model processing
The model was downloaded from Thingiverse, but couldn’t be used directly. Therefore, we imported the model to Solidworks directly (since it is already a low-poly model) and sliced it in half. Due to the fact that it is symmetry in both the x and y axis, we can have the same model for both CNC and 3D printed parts. (Yet we didn’t realize this first and made different models for them, which resulted in incorrect locating holes).
3. Positive Mold
The next step is to produce the positive model using the two methods. The 3D printed one is rather simple, as we had a lot of experience with it. The CNC one, however, is really a pain for us. We set up the file correctly and initially, we decided to use the Nomad 3 to produce the model, but it took too long for the book time to finish the model. For the second trial, we started at the Shapeoko and moved back to Nomad for finishing. But we didn’t set up homing well and there is an offset when finishing. The second trial is then also concluded as a failure. For the third trial, we decided to do everything on Shapeoko to avoid the difference in locating. However, the machine failed constantly since it stuck when moving the x-axis in a certain location. The fourth time, we figured that we had to manually push the machine at some place to help it move. After a stressful hour, we finished cutting out the mold.
4. Negative Mold
Then, we used cardboard paper and wrapped the positive mold. With hot glue, we made sure that there won’t be leaking when pouring silicon in. After mixing up the silicon and waiting for half a day, the negative mold is finished.
5. Apply Liquid Plastic
With the help of TA, we applied two layers of cardboard outside the mold so the rubber band wouldn’t cut through the mold. Then we mixed liquid plastic with various add-ins, like dye and glowing powder.
We then poured it into the mold and waited for it to solidify.
After eight repetitions, we got the eight towers we wanted. To make it more interesting, we even made one with epoxy resin. (the one with a more transparent outlook)
6. Post-processing
We noticed the tower isn’t as smooth as we expected (mainly for the CNC part), so we used sandpaper to make the bottom and the connection part smoother.
And after doing this to all nine of them, the tower is finished!
Cost Analysis:
- Material
- 3D printing: $0.2
- CNC wood: $12
- Silicone:$2.5
- Liquid Plastic: $10
- Epoxy Resin: $2
- Dye: <$0.1
- Glowing Powder: $2
- Other materials like cups, rubber bands, cardboard, and stirring rod: $5
- Labor
- 10 hour* $12/hr*2 people =$240
Sum: $273.8
