Nic, Andy, and Alejandro Chess Piece | ENGI 210: Prototyping and Fabrication

Final Project. The meat. The rest of the year was the potatoes, except the midterm that was like a hefty chili as an appetizer. I’ll explain the context. 2 casts 8 molds of one with a test of the wampa. The project was done simultaneously. Every step, unless otherwise specified, is expected to be replicated on the other. I will base this project off of the Wampa from Mario from my perspective. 2 PROJECTS!

Step 1: Create the file from Thingiverse. Download the initial print, split the part in half, affix the backing to the wampa. The split was done on mesh mixer in order to get a more accurate split because the whole program is dedicated to manipulating .STL files. After exporting, going into Solidworks was difficult as I am used to Fusion360 but they all work just the same. Download the backing and affix to the wampa half with a few mates and line up the piece. This piece is now ready for printing at the OEDK. Slice the file in the prusaslicer program or similar program for .gcode and print.

Step 2: After the piece is printed out create a box around the edges of the printed part and create a seal on all edges so that the silicone does not pour out. Calculate a rough estimate of the volume of a little bit above the highest part of the printed part. Mix parts of the silicone pours in 1:1 ratios in volume to match the volume of the rough estimate calculated before. Mix the 2 parts until completely mixed. Pour slowly and wait until solid.

Step 3:

The next step of the process is to create the vcarve files needed to use the CNC machine in 3 dimensions. Unlike the Carbide create tool, vcarve is made specifically for 3D models. Insert the .stl that you want to use and begin by making a roughing pass with a 1/8 size bit with the job size (wood) to complete the part. Finally make a finishing pass with a 1/16 bit to make it look nice and neat. This is longest part of the project.

Step 4:

Finally, repeat the mixing portion of step 2 but with the addition of adding sides to the wampa because it went off of the wood.

Step 5:

Finally the molds are done. Place both molds together with rubber bands, tape, or your hands if you want a work out. Mixing the plaster of paris to proper ratios, pour in the plaster into the molds and let sit until dry.