For this week I wanted to challenge myself a little. Since I have previous knowledge with molding and casting I wanted to try to make a mold from more than two parts.
My plan was to start out with what I was sure was a simple form and later evolve into something more complex. And I decided that I was going to cast Chocolate.
My regular tool of choice for CAD is SolidWorks but since I got a new mac I haven't had the chance [or the courage] to install the program so here's what I did using Rhino.
At first I tried to make a tetrahedron
freehand using the tools I know in Rhino.
Here are my steps for this shape:
1. I made a Pyramid using Rhinos Solid tools.
2. To hollow the shape I made an Offset srf to each of the shapes surfaces.
3. Then I used Trim until I had the shape hollow.
4. To make the surfaces into a solid i Joined them.
5. I then copied the shape inside and closed it to have the solid of the inner space.
6. For the outer part of the mold I again used offset srf.
After I thought I was done molding the shape I wanted I checked to see if it's symmetric and to my (not so happy) surprise it wasn't. While I did try through methods I thought right to make a perfectly symmetric tetrahedron it didn't work and the result was something close but not quit what I was aiming for. So I went and redid everything only better this time. I found a the shape online and downloaded it free here.
For the second model I used the same steps and added some more to make the molds.
I made the molds using Modela. I made a few tests before milling the final part but didn't have enough time to really play with it, because there was a line to use the machine and because I had to make a mold from five parts and that takes time. I am planning on making more tests soon so I can improve my mold.
Due to the complexity of my molds I didn't work with a 1/32" milling bit, instead I used 1/8" bit for both the rough and the finish. It wasn't as smooth as I would have wanted but I did manage to smooth some parts using a heat gun blower. It wasn't perfect but it worked. Not recommended for precision.
To make chocolate I planned to cast the mold out of non toxic silicon we have in the lab. It took 16 hours to cure, then it was in the oven for three hours and only then it was ready for molding.
When the silicon molds were ready I put them together only to find that I made a mistake and the outer mold was 5mm too short. Luckily I can fix it by recasting the silicon.
As you can see the chocolate from the first cast was too thin so I wasn't able to detach it without braking the chocolate completely. Since I still had a lot of chocolate and I wanted to cast more I took only the outer mold and created simple shapes. The smaller parts are from the negative space I had planned for the inner mold.