Low budget tool making.
 

Hello,

for fiber composite parts it is important to make molding tools.

CNC molding tools are expensive so I decided to make the tool at the workbench.

You need a 3D geometry and cut-curves.

For symmetric molding tools, I used wooden templates to cut with a hot wire.

https://www.youtube.com/watch?v=iNs6...1PLQ1PFOI_3HGA

https://farm9.staticflickr.com/8323/...027883_z_d.jpg
Then I cut styro plates.
Following pictures and the video gives yo a overview, how to make the tool.
https://farm9.staticflickr.com/8047/...7a790e_z_d.jpg
https://farm9.staticflickr.com/8336/...a60310_z_d.jpg
https://farm9.staticflickr.com/8475/...537c67_z_d.jpg
https://farm9.staticflickr.com/8193/...c3686a_z_d.jpg

Kind regards
Ulrich

8 Thanks and no comments?

Have you seen http://ecomodder.com/forum/showthrea...eat-22529.html? One of our members is (slowly) building a whole car that way.

It will work
 

Yes, I saw this and I think it will work.

Ulrich

Details
 

In this photo gallery you will find some more details.

Xanon Bionic Electric Vehicle - Xanon-X3 Werkzeuge Formenbau - Werkzeuge und Formenbau

The inner airbox and expansion chamber were made by lost tools.
http://www.xanon.de/images/phocagall...l__MG_1524.jpg

Thanks for the pictures and links. Nice work.

I've done something similar in the past, but skipping the 'wooden template' step by simply using a projector to project sections onto the material (calibrated by use of a ruler matched to the projected image), then tracing with a texta.

Initially doing the cutting with an electric jigsaw, but that created a *lot* of nuisance dust - you ain't seen nuisance dust 'till you've seen polystyrene nuisance dust, the stuff electro-sticks to *everything* :p . Turns out a snap-off blade utility knife with the blade fully extended, and held at a fairly low angle to 'drag' through the polystyrene, works much better and produces a nice clean cut (and doesn't produce the nasty gasses that a hotwire does).

For what I was doing I didn't need the precision you get from u.steinlechner's more traditional method, but I reckon you could get the best of both worlds (precision and even less cost) by printing the profiles on large format paper at an office supply store, and using a utility knife for the cuts.

I must say though, the hot wire produces some very nice circular holes :thumbup:

here's a comment: "WOW :eek:....no really WOW! :thumbup: :thumbup: :thumbup: :thumbup: :thumbup: :D

http://ecomodder.com/forum/member-fr...e6263-tool.jpg

An vintage tool from the 60s. It was US$1.99 at a second hand store, and uses 2 D-cells.

Try a knife blade instead of a saw blade in the jiggler saw. It works great on corrugated cardboard, and should do well on stryofoam.

I really like the construction methods of carBEN. Too bad nature conspired against it! I am glad that was not worse!

I bought the nichrome wire to make a wire cutter, but connecting it to my battery charger did not do anything, although I have charged batteries in two different Civics with it.

cutter
 

The late Bob Parsons had a 'VARIAC',variable-voltage,DC power supply that he used for hot-wiring.It's like a larger version of a scale model train transformer.
Once you dial in an acceptable output,you're golden.
Alexander Sport Air used them at Oshkosh during their annual Fly In workshops.
I found one in Dallas at the monthly electronics swap meet for $35.