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Unread 14-10-2010, 11:39
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Re: pic: How 125 is rolling this year...

Those look very nice, I'd love to see how well they work out on an actual drivetrain.
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Unread 14-10-2010, 13:42
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Re: pic: How 125 is rolling this year...

Quote:
Originally Posted by Bruceb View Post
Has anyone else tried this? Any success? Brando, what mods did you come up with for this wheel? Can I get a picture of the actual mold? I don't quite get how you get the entire wheel molded on all sides without any machining.
Thanks
Bruce
Here is a picture of just the mold



If you don't mind small imperfections on the face of the wheel then you don't need to worry about machining. Because you are using silicone as your actual mold cavity, the regular rules of molding can be stretched. Things like undercuts and 0 degree draft can be done because the silicone is compliant and moves out of the way of the way of the part when removing it from the mold.


Quote:
Originally Posted by r2davis2 View Post
Those look very nice, I'd love to see how well they work out on an actual drivetrain.
These wheels are from our 2010 robot, so they were in this past years competition. Changes are in the works to make them even more reliable, cheaper, faster to turnover and easier to make.

-Brando
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Unread 14-10-2010, 14:34
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Re: pic: How 125 is rolling this year...

So, to make the mold you just laid the master on the bottom of the mold box and poured the silicone over it? The top side of the wheel is as smoothe as the urethane was poured, correct? Or did you pour it high and machine off the excess?
Bruce
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Unread 14-10-2010, 16:03
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Re: pic: How 125 is rolling this year...

Quote:
Originally Posted by Bruceb View Post
So, to make the mold you just laid the master on the bottom of the mold box and poured the silicone over it? The top side of the wheel is as smoothe as the urethane was poured, correct? Or did you pour it high and machine off the excess?
Bruce

The mold "box" base was an aluminum plate with the bolt hole pattern drilled into it. This was then used to hold the master (aluminum) wheel down to the plate. I then hot glued a bucket with the bottom cut off around the wheel.

Yes, the top side is as smooth as the urethane is poured. Some of our wheels have just the poured urethane surface on top. As we tweaked the process though, we added more glass to the urethane, which resulted in a "bumpier" surface on the top. To enhance the look of the wheels we did start pouring high and machining the excess away. One of the enhancements to the process we are trying to make is to eliminate that step, although it only takes a minute or 2 for that operation per wheel.

-Brando
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Last edited by Brandon Holley : 14-10-2010 at 16:11.
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Unread 14-10-2010, 16:14
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Re: pic: How 125 is rolling this year...

What is your final chopped glass to resin ratio? Are you still using 1/2 inch pieces of glass or have you gone shorter?
Bruce
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Unread 15-10-2010, 08:46
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Re: pic: How 125 is rolling this year...

Quote:
Originally Posted by Bruceb View Post
What is your final chopped glass to resin ratio? Are you still using 1/2 inch pieces of glass or have you gone shorter?
Bruce
Our pieces of glass are between 3/8" and 1/2". Right now to measure the amount of fiber we place in the mold, we place the chopped fibers in a cup and gently tap the cup on a table to flatten the fibers out a little bit. We use the same style cup to measure out the urethane needed for the wheel. We then use a 1:1 ratio of urethane to "tapped down" fiber by volume. Our wheels typically needed about 80 mL to fill the wheel safely, so obviously for the 80 mL of urethane, we needed around 80 mL of tapped down chopped fiber.

The amount of fiber we use is something we still want to play around with. I feel with the geometry tweaks we plan on making that we can reduce the amount of fiber necessary.

-Brando
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Unread 15-10-2010, 10:55
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Re: pic: How 125 is rolling this year...

Have you looked into buying precut fiberglass? You can get in in pretty short lengths that might mold better.
Bruce
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Unread 15-10-2010, 13:49
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Re: pic: How 125 is rolling this year...

Quote:
Originally Posted by Bruceb View Post
Have you looked into buying precut fiberglass? You can get in in pretty short lengths that might mold better.
Bruce
We used chopped fiber at the time because we had cloth laying around that we could use right away. Certainly playing with the size of the fiber would be another variable to explore, and is something we'll certainly be looking into.

-Brando
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2012 New York City Regional Winners, Boston Regional Finalists, IRI Mentor of the Year
2013 Orlando Regional Finalists, Industrial Design Award, Boston Regional Winners, Pine Tree Regional Finalists
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