10. Molding and casting

Introduction:

During the molding and casting week for Fab Academy, my primary objective was to enhance the realism of suture practice pads, which led me to explore various molding and casting techniques. Initially, I aimed to create a comprehensive solution by molding an entire hand and integrating 3D printed bones into silicone for lifelike practice products.

The concept sought to strike a balance between authenticity and feasibility, with the integration of 3D printed bones offering intricate detail and practicality for suturing practice. While the idea was captivating, I recognized the need for meticulous planning and execution to ensure its success.

Project Planning and Preparation:

To kick things off, I outlined my main goal: making suture practice pads more realistic using molding and casting. I did some digging to find the best materials and techniques for the job. This included looking into what would make the casts durable, flexible, and detailed.

I also needed a good 3D model of human hand bones to start with. Getting the size right was key to making sure the casts looked and felt real. I checked out different 3D printing methods, like SLA and FDM, to see which would work best for making the bones and molds.

Before diving in, I wanted to test out my plan on a small scale. So, I made some simple molds and poured in silicone to see how it turned out. This helped me figure out what might work and what might need tweaking. I also made a timeline to keep me on track with deadlines and milestones.

By planning things out carefully, I set myself up for success and made sure I was ready to tackle the next steps.

BONES:

FDM MOLD TEST:

SLA MOLD TEST:

CNC MACHINING MOLD TEST: