IDEA / MSET Q4 · 2025–26 · DOC: MSET-MOLD-02
MOLD BODY DESIGN
ASSIGNMENT 02 — NEGATIVE MOLD CONSTRUCTION
How to Use This Document►
Submission
Click EXPORT HTML (primary button). Submit the exported file to Google Classroom. Also submit your .SLDPRT file separately.
Saving
Auto-saves every 30 seconds. Click SAVE PROGRESS anytime. Toggle auto-save on/off with the toolbar button. Last save time appears top-right.
Collapse Modules
Click any module header to collapse or expand it. Collapsed state is saved between sessions.
Approval Gate
Modules 05 and 06 are locked until Mr. Pina enters the approval code. Complete all CAD work in Modules 01–04 first.
Images
Click upload zones, drag files in, or paste with Ctrl+V. The cyan PASTE TARGET badge shows where Ctrl+V will land. Click any image for fullscreen.
Dual-Unit Fields
Dimension fields show inches and mm side by side. Enter either — the other auto-fills.
Measurement Table
In Module 06, document actual vs. designed dimensions. Click Expand for fullscreen. Drag rows to reorder. Duplicate rows to copy.
Background
Move your mouse to illuminate the grid. Panels and images lift on hover.
SUBMISSION INSTRUCTIONS
1.Complete Modules 01–04 and present your SolidWorks file to Mr. Pina for approval before continuing.
2.After approval, complete Modules 05–06 including physical print documentation.
3.Click EXPORT HTML. Submit the exported file to Google Classroom.
4.Submit your SolidWorks multibody part file (.SLDPRT) to Google Classroom separately.
MODULE 01
Mold Block Creation
12 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 12 | Geometry confirmed. All six face offsets documented and meeting minimum 5.00mm / 0.197". Image uploaded. All confirmations checked. |
| 8 | Offsets documented but one or more faces below minimum, or image missing. |
| 4 | Partial. Several offsets missing or confirmations incomplete. |
| 0 | Not submitted. |
Starting geometry: your drafted part and its defined parting reference plane must be complete before beginning this module. The parting plane is the sketch plane for the boss extrude and the trimming surface for the split in Module 02.
STARTING GEOMETRY CONFIRMATION REQUIRED
Confirm your part has correct draft angles on all faces and the parting reference plane is defined. (1–2 sentences)
0 / 1–2 sentences
Dual-Direction Boss Extrude — Face Offset Documentation
Three steps:
1. Open a sketch on the parting reference plane.
2. Sketch a rectangle covering the full footprint of your part with clearance on all sides.
3. Extruded Boss/Base — set Direction 1 depth (above parting plane) and Direction 2 depth (below parting plane) so the block encapsulates the part with material on every side.
Minimum offset: 5.00mm / 0.197" from every part surface to the nearest outer mold wall. Walls below this crack, flex, or fail during demolding.
1. Open a sketch on the parting reference plane.
2. Sketch a rectangle covering the full footprint of your part with clearance on all sides.
3. Extruded Boss/Base — set Direction 1 depth (above parting plane) and Direction 2 depth (below parting plane) so the block encapsulates the part with material on every side.
Minimum offset: 5.00mm / 0.197" from every part surface to the nearest outer mold wall. Walls below this crack, flex, or fail during demolding.
Measure from the extremity of your part geometry outward to the outer face of the block — not from the parting plane outward.
Enter your actual offset from part surface to outer mold wall for each face. Inch and mm fields auto-sync. All six faces must show green before continuing.
| Face | Offset (in) | Offset (mm) | Status |
|---|---|---|---|
| Top | — | ||
| Bottom | — | ||
| Left | — | ||
| Right | — | ||
| Front | — | ||
| Back | — |
Enter all six face offsets to check compliance.
MOLD BLOCK VIEW MIN 1 IMAGE
Use wireframe mode or set the block body to transparent so the encapsulated part is visible inside.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
CONFIRMATIONS
MODULE 02
Subtractive Combine & Split
12 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 12 | Both operations documented. Cavity confirmed with no geometry errors. Two resulting bodies confirmed. Images uploaded. |
| 8 | One operation underdocumented or one image missing. |
| 4 | Partial. Key confirmations missing. |
| 0 | Not submitted. |
Subtractive Combine
Insert > Features > Combine — Operation Type: Subtract
Main Body: the extruded block (the body you keep).
Bodies to Subtract: your drafted part (the shape being carved out).
Result: the block with the part geometry removed. That negative shape is your mold cavity. The drafted part body is consumed by the operation.
Main Body: the extruded block (the body you keep).
Bodies to Subtract: your drafted part (the shape being carved out).
Result: the block with the part geometry removed. That negative shape is your mold cavity. The drafted part body is consumed by the operation.
Tip: enable "Make main body transparent" in the PropertyManager to make selecting the part body easier when the two bodies overlap.
▶ VIDEO — Subtractive Combine
COMBINE OPERATION REQUIRED
Identify your Main Body and the body being subtracted. Confirm the result. (1–2 sentences)
0 / 1–2 sentences
CONFIRMATIONS
Split
Insert > Features > Split
Trimming Surfaces: select the parting reference plane directly. Planes extend infinitely — no sketch is needed.
Click Cut Bodies. Two bodies appear under Resulting Bodies.
Select both, assign names (e.g., MoldTop and MoldBottom), and click OK. Both halves remain in the same multibody .SLDPRT file throughout this assignment. ▶ VIDEO — Split Feature
Trimming Surfaces: select the parting reference plane directly. Planes extend infinitely — no sketch is needed.
Click Cut Bodies. Two bodies appear under Resulting Bodies.
Select both, assign names (e.g., MoldTop and MoldBottom), and click OK. Both halves remain in the same multibody .SLDPRT file throughout this assignment. ▶ VIDEO — Split Feature
SPLIT RESULT REQUIRED
Confirm the split produced two clean named bodies. (1–2 sentences)
0 / 1–2 sentences
CONFIRMATIONS
VIEWS MIN 2 IMAGES
Image 1: transparent or cross-section view confirming the cavity. Image 2: both mold halves visible in the part after the split.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 2 required
MODULE 03
Bolt Holes
14 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 14 | Bolt size selected and documented. Hole diameter and bolt length match calculator output. Placement rationale written. All confirmations checked. Image uploaded. |
| 9 | Bolt size and hole diameter documented but rationale missing or image absent. |
| 5 | Partial — bolt size selected but fields largely incomplete. |
| 0 | Not submitted. |
The bolt hole cut can be performed before or after the Split — both work. If done before, set Feature Scope to All Bodies so both halves receive the hole. If done after the Split, run the cut twice using Feature Scope to target each half body separately. Either way the hole must pierce both bodies completely.
Standard Close Fit Hole Diameters for 3D Printed HIPS
| Bolt Size | Nominal Shank (in) | Nominal Shank (mm) | Design Hole (in) | Design Hole (mm) |
|---|---|---|---|---|
| 6-32 | 0.138" | 3.51mm | 0.150" | 3.81mm |
| 8-32 | 0.164" | 4.17mm | 0.176" | 4.47mm |
| 10-32 | 0.190" | 4.83mm | 0.202" | 5.13mm |
| 1/4-20 | 0.250" | 6.35mm | 0.262" | 6.65mm |
Design hole = measured shank + 0.012" / 0.3mm close fit compensation for 3D printed HIPS. Use the calculator below if your bolt measures differently.
- Confirm you are working BEFORE the Split feature in Module 02. Roll back the end of history bar if needed.
- Create a sketch on the top face of the mold block.
- Place circles at your chosen bolt hole locations — minimum 2, positioned so bolts clear the cavity and parting features. Keep at least 0.315" / 8mm from any outer mold wall edge.
- Extruded Cut — set direction to Through All Both Directions so the cut passes completely through the full mold height regardless of body count.
- Feature Scope — leave set to All Bodies. Both halves will receive the hole when the Split runs later.
- After the Split, verify the hole aligns across both parting faces when the halves are mated.
BOLT HOLE CALCULATOR
MEASURED SHANK DIA (in)
TOTAL MOLD HEIGHT (in)
Hole dia: —
Bolt length: —
Documentation
BOLT SIZE SELECTED REQUIRED
DESIGNED HOLE DIAMETER REQUIRED
/
DESIGNED BOLT LENGTH REQUIRED
/
BOLT PLACEMENT RATIONALE REQUIRED
Where are the bolts placed and why does this location clear the cavity and outer walls?
0 / 1–2 sentences
CONFIRMATIONS
BOLT HOLES VIEW MIN 1 IMAGE
Use wireframe mode or set the mold body to transparent. Both the top face hole locations and a cross-section or side view showing the hole passing through the full mold height are recommended.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
MODULE 04
Pour Spout
14 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 14 | Pour orientation, highest cavity point, and flat zone rationale all documented with clear reasoning. Spout specs meet minimums. All confirmations checked. Image uploaded. |
| 9 | Spout present and plausibly located but rationale fields sparse, or one spec below minimum. |
| 5 | Spout created but placement undocumented or reasoning missing. |
| 0 | Not submitted. |
The spout must satisfy two constraints simultaneously:
1. Highest cavity point. When the assembled mold sits in pour orientation (level on a surface), the spout must be at or above the highest point of the cavity. If the cavity rises above the spout, air gets trapped and the cast will be incomplete.
2. Flat featureless zone. The spout must break through a flat area of the upper half's top face with no part detail geometry directly below it. This prevents the sprue (cured material in the channel) from tearing detail off the cast part when removed.
These two constraints sometimes conflict. Adjust mold orientation or spout position until both are satisfied. Document your reasoning in the fields below.
1. Highest cavity point. When the assembled mold sits in pour orientation (level on a surface), the spout must be at or above the highest point of the cavity. If the cavity rises above the spout, air gets trapped and the cast will be incomplete.
2. Flat featureless zone. The spout must break through a flat area of the upper half's top face with no part detail geometry directly below it. This prevents the sprue (cured material in the channel) from tearing detail off the cast part when removed.
These two constraints sometimes conflict. Adjust mold orientation or spout position until both are satisfied. Document your reasoning in the fields below.
The spout is a cut extrude — Feature Scope set to upper half body only. Apply 1-2 degrees of draft so the spout is slightly wider at the top than at the cavity entrance, enabling clean sprue release on demolding.
POUR ORIENTATION REQUIRED
Describe how the assembled mold sits during a gravity pour. Which face rests on the surface? (1–2 sentences)
0 / 1–2 sentences
HIGHEST CAVITY POINT REQUIRED
In the pour orientation described above, which area of the cavity is highest? (1–2 sentences)
0 / 1–2 sentences
FLAT FEATURELESS ZONE RATIONALE REQUIRED
Where on the top face of the upper half is the spout placed, and why does no part detail exist directly below it? (2–3 sentences)
0 / 2–3 sentences
Pour Spout Specification
Cut extrude on top face of upper mold half. Feature Scope = upper half body only. Apply 1–2 degrees of draft to the cut so the channel is slightly wider at the opening than at the cavity entrance.
SPOUT DIAMETER MINIMUM 10.00mm / 0.394"
/
Enter diameter to check compliance.
DRAFT ANGLE 1–2 DEGREES
Draft applied to the spout cut — wider at the top, narrowing toward the cavity. Enables clean sprue release.
degrees
—
CONFIRMATIONS
POUR SPOUT VIEW MIN 1 IMAGE
Show the spout on the upper half and an assembled mold view illustrating the pour orientation.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
INSTRUCTOR APPROVAL REQUIRED
Complete Modules 01–04 and present your SolidWorks file to Mr. Pina before continuing to print settings and physical documentation.
ACCESS GRANTED
MODULE 05
Print Settings
8 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 8 | Machine selected. All settings confirmed. Bambu Studio screenshot uploaded showing sliced mold with settings visible. |
| 5 | Settings confirmed but screenshot missing or unclear. |
| 2 | Partial. Several settings unconfirmed. |
| 0 | Not submitted. |
PRINTER SELECTION REQUIRED
Required Settings — Confirm Each Before Slicing
Choose one. Variable layer height gives better cavity surface resolution but requires manual setup in the layer height editor. The 0.18mm preset is faster and still produces good results.
Both mold halves must be exported as separate STEP AP214 files from the multibody .SLDPRT for use in Bambu Studio or other software. For each half: (1) In the FeatureManager, expand the Solid Bodies folder. (2) Right-click the body name (e.g. MoldTop). (3) Click Save As. (4) In the Save As dialog, set file type to STEP AP214 (*.step / *.stp). (5) Click Options — ensure Selected Bodies is chosen, not the entire part. (6) Click OK, then Save. Repeat for the second body. You will end up with two separate .step files — one per mold half — ready to import into Bambu Studio as individual objects.
BAMBU STUDIO SCREENSHOT MIN 1 IMAGE
Show the sliced mold with the settings panel visible. Both halves should appear on the build plate.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
MODULE 06
Physical Print Result
20 PTS
▼
| PTS | DESCRIPTOR |
|---|---|
| 20 | Photos of both halves and assembled mold uploaded. Minimum 2 dimensions verified. Surface quality documented. All confirmations checked. |
| 14 | Photos present but one measurement missing or surface notes sparse. |
| 7 | Photos present but documentation largely incomplete. |
| 0 | Not printed / not submitted. |
PRINTED MOLD HALVES MIN 1 IMAGE
Both halves visible — cavity faces preferred.
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
ASSEMBLED MOLD WITH PINS ENGAGED MIN 1 IMAGE
PASTE TARGET
Drop, paste, or click to upload
0 images — minimum 1 required
Dimensional Verification — Minimum 2 Measurements
Measure at least two key dimensions on the printed halves with calipers. Compare to your SolidWorks model. Both unit columns auto-sync.
| Measurement | Designed (in) | Designed (mm) | Actual (in) | Actual (mm) | Delta (mm) | Status |
|---|
SURFACE QUALITY NOTES REQUIRED
Describe cavity surface quality, alignment pin fit, and overall mold readiness. (1–3 sentences)
0 / 1–3 sentences
CONFIRMATIONS
Print Queue
Submit print jobs to Mr. Pina — attach files before sending
Use this tool to submit your mold half print jobs. Fill in a card for each part you need printed, then use the email button to open a pre-filled message to Mr. Pina. Attach your 3MF or STEP file before sending.
⚠ USE THIS ONLY IF ALL 3D PRINTERS ARE UNAVAILABLE. If any printer is free, print directly. This queue is a last resort for when every machine in the room is occupied.
ACADEMIC INTEGRITY DECLARATION
By submitting this assignment, I confirm that all written responses, design decisions, and documented values in this file reflect my own work. AI assistance is permitted for research, writing, and workflow guidance. All SolidWorks operations and physical measurements must be performed by me.
By submitting this assignment, I confirm that all written responses, design decisions, and documented values in this file reflect my own work. AI assistance is permitted for research, writing, and workflow guidance. All SolidWorks operations and physical measurements must be performed by me.
AI USE NOTE — AI assistance is permitted for all portions of this assignment. Caliper measurements and SolidWorks work must be your own.
| MODULE | MAX | EARNED | NOTES |
|---|---|---|---|
| 01 — Mold Block Creation | 12 | ___ | |
| 02 — Subtractive Combine & Split | 12 | ___ | |
| 03 — Bolt Holes | 14 | ___ | |
| 04 — Pour Spout | 14 | ___ | |
| 05 — Print Settings | 8 | ___ | |
| 06 — Physical Print Result | 20 | ___ | |
| TOTAL | 80 | ___ |
SUBMISSION CHECKLIST