Make a mould to extrude beams
Beams make great use of the extrusion machine as they can be strong and enable you to create very unique patterns and colours. This guide will show you how to make a mould which can be easily translated to any size of beams.
(Update: We also added a lasercut version, see step 7!) —
Step 1 - Get ready
To make a beam mould you will need:
- Metal tube (Preffereably with a wall thickness of 3mm or more)
- Angle iron
- Metal sheet (3mm or more)
- Threaded pipe or fitting (BSPT size of your nozzle)
- Angle grinder / Metal saw
- Welding machine
- M8 or M10 nuts & bolts
Step 2 - Cut beam
Pro tip: It's important to remove any burrs and file the edges here, as this will ensure a better fit in the stages to come. Cut a thin slice extra to use as a template to use in the step 4.
Step 3 - Make mounting brackets
Pro tip: This is a relatively simple process.. so you can save some time here by making lots of brackets in different sizes at once. When you need to make more moulds in future you'll thank yourself for that little extra you put in.
Step 4 - Cut and plan plate
Pro Tip: Use the thin section of your beam from step 2 as a template for marking the position of your brackets and their holes.
Cut the sheet, drill the holes.
Step 5 - Welding the mould
Then position where you want your plastic to enter the mould and weld the threaded nozzle to the to other side of the plate.
Step 6 - Finishing up
This should yeild one straight hole all the way through.. but if thats not enough, or you still find there are some undercuts, you can use a larger bit to open the plate more on the beam side.
Step 7 - Lasercut version!
We added a .zip file with drawings you can use or send to a lasercut company to cut your parts.
These plates are going to replace the use of brackets for making the beam mould.
After you receive the plates you'll need to place them on the beam by gently tapping them with a rubber hummer, making sure it's perpendicular and flush with the beam. To check this you can put the nozzle plate in front of it to make sure it's not in an angle.
After this you can proceed to weld everything in place.
Step 8 - Explore the possibilities!
There is a lot to explore, you can get some inspiration in other How-to's!
Make glass like beams
Extrude different textures
Make T-shaped beams
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