Design of simple multi-use thermoforming molds for the beginner machinist designer

Abstract

The aim of a class with Engineering Design points at MIT is to help the students learn how to put into practice different lessons and techniques in engineering a product. Beginner machinist are sometimes held back by the time consuming process of constructing proper housing in electronic dominant disciplines. The aim for this thesis was to devise a simple multi-use molding system to facilitate learning for the beginner machinist. Five schemes were used in conjunction with seven shapes and sixteen different detail designs to come up with thirty seven molds, out of the five hundred and sixty mold possibilities, which students may use in multiple ways. Choosing Renshape®5025, a polyurethane based thermoset foam for the mold material, allows the limited facility in the EDS lab to repair and manufacture a variety of mold designs. With the addition of plywood base board for added weight and grip ensures that the forms are easily removed without damaging the molds.