Wooden Frisbe Mold Press

The project I am making is a wooden mold that can be used to press hot plastic sheets into frisbes

I used just our CNC router and a piece of 20x13 wood

For my prototype I first made a model of a frisbee and 3d printed it out to get the shape and size I wanted. I need made a sketch of the mold I would cut out.

I first had the idea to make a mold that could be used to extrude plastic into it, but that became too hard to design/manufacture, so I moved on to just pressing the sheets into the shape. I first made a basic frisbee in CAD to make the mold around. I made the frisbee by making a 2D shape and extruding it in a revolve so it makes a full circle.

I then form a square around the made frisbee and extruded it to cover the entire frisbee alowing me to use the combine tool the seperate the frisbee from the block.

I first faced the bottom of the wood so it would sit well on the CNC router. I then made a CAM design that faced the top of the piece as well as cut out the divot using two different operations. The first operation cut out a circle that formed the bottom flat part in the top mold. The second operation cut out steps along the edge of the curve and then went through with a ball endmill to round it out.

For the second piece I just attached it to the surface of the CNC router and made a CAM design that made steps on the outside of the piece to then make it easier for the ball endmill the make the piece curved

The finished product is two pieces one to from the top of the frisbee and the other to from the bottom this allows the frisbee to from properly in the mold