So, DialFonzo, this may not be exactly what you're looking for, but it's from the beginning.
First, a tour of my spacious 14 sq. ft. shop.
uprightshop.jpg [ 3.1 MiB | Viewed 591 times ]
Yeah, that's it.
Step 1: Design
Untitled.png [ 138.67 KiB | Viewed 591 times ]
I'm going to follow the production of the highlighted part.
Step 2: Create a mold cavity with a 5-6mm margin from the part. I cut it close in this case due to space constrictions.
Untitled2.png [ 116.92 KiB | Viewed 591 times ]
For each case I will make the mold walls at least 3mm taller than the part. As long as you cast on a flat surface then this margin isn't extremely important.
Step 3: Mate the parts, set origin according to the CAM program you use.
Untitled3.png [ 118.38 KiB | Viewed 591 times ]
Step 4: Create CAM profiles. Honestly, my mill is nothing to write home about. Rigidity is not a strong point. Smart tool paths are the key.
CAM.png [ 224.1 KiB | Viewed 591 times ]
Rough at reasonable margins and finish with levels that you've experimented with and know produce good results.
Step 5: Machine
20121009_211748.jpg [ 2.87 MiB | Viewed 591 times ]
A shot taken during the final finishing cut creating the filet on the edge.
Step 6: Finished Mold
20121009_230327.jpg [ 2.21 MiB | Viewed 591 times ]
The explanation ends here for now. I'm still waiting on some parts so I'll discuss the silicone and polyurethane casting afterwards.