On Wed, May 24, 2017 at 8:33 PM, Forest Crossman <cyrozap@gmail.com> wrote:
> I'm not sure how complicated the parts of the laptop case are, but if the parts could be re-designed to be optimized for resin casting, it might cut down on the production time. Of course, I've never done any resin casting before so I don't know how feasible this would be in practice. Also, I have no idea how fast modern 3D printers can run now, so the speed advantage might not even exist any more.
I've got a tiny bit of experience here, for what it's worth. For our open source SMT pick and place machines, we used 3D printed molds for mass-producing a particular part on the machine. They were cast in medium to low durometer urethane, but the process is somewhat similar to other types of resins.
The main problem we had were that the molds took a while to clean. The material oozed out of the top in a few strategically placed holes. Those would clog constantly and required a lot of labor to clean, however, probably still MUCH less than if the parts were 3d printed. So it was slightly annoying, but less annoying and quicker than 3D printing that particular part. There are prototyping shops in China that can do this in limited runs, with great results. No idea about cost though.
The surface finish was actually quite nice. It was basically an inverse of the 3D printed part. It looked 3D printed, but under magnification, you could see that the the ridges were backwards. If the master parts were 3d printed via an SLA process, then those lines would disappear, and the accuracies would be much better. We usually got very small air bubbles on the surface of the part, but it was casted upside down so they were never seen.
Probably the main detractor for resin casting in this particular case is going to be how the parts are designed. Unless a part was designed to be cast, it's probably not going to be cast. lkcl has already spoken that he did not want to redesign any of the parts if he could help it. For that reason alone, I'd guess that it's probably off the table.
I'm definitely not an expert though, this is not really my area. Just figured I'd share my brief experience.