The design I made for molding and casting is a cover for my USBtiny IS. I imported the PCB from Eagle to Fusion and drew the main components, since their 3D model was not available in my Eagle ligrary
Then I designed a cover with in taking into account the dimensions of the pin headers and the USB connector
Using boolean operations I got the Negative mold.
The positive mold is obtained from the negative mold with a simple boolean.
The first milling operation is adaptive clearing with a 5mm flat end thread
The second milling operation is pocketing with a 3mm flat end thread
The last milling operation is smoothing the edges with a 1mm ball nose, with a ramp pattern.
Wax mold (positive)
Silicon mold (negative)
The edges of the wax mold were not smooth as expected. Perhaps the ramp smoothing was not the best setup, or the increment was to big