Molding and casting

Group assignment: -Review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them compare mold making processes
Group-Molding and casting

Individual assignment:
-Design a mold around the process you'll be using,
-produce it with a smooth surface finish that does not show the production process toolpath, and use it to cast parts

Steps to make a mold
1. Designed the Master Model

• Design an object to mold and 3D printed it
• Ensure surface is clean and smooth

2.Prepare the Master and Mold Box

• Printed the mold box to be used
• Clean the object and apply silicone mold
• Put it on the flat surface to avoid imbalance




• My mold is 3D printed, and below are the post processing done.
• The mold pieces to post process

• Tools used to smoothen the mold pieces

I used Rotary tool IDE grinder and sand paper to smoothen the mold




• The video demostrates how the smoothening of the mold is done.
• Before cleaning

• After cleaning with water

3.Measure and Mix Silicone Rubber

• Use a 2-part silicone rubber kit
• Mix Parts A and B thoroughly with the ratio: 1:1
• Stir slowly to avoid air bubbles

4.Degas the Silicone (Optional)

• Use a vacuum chamber for 2 minutes
• Let bubbles rise and collapse before pouring

5.Pour the Silicone into the Mold Box

• Pour slowly from the opening stream
• Let silicone flow around the object naturally
• Tap or shake mold box gently to release bubbles

6.Cure the Silicone Mold

• Let the silicone cure undisturbed for 4–24 hours
• Time depends on product and room temperature

7.De-mold the Silicone

• Remove mold box
• Carefully extract the master
• Trim excess material or flash

Molding post processes

Post-Processing on Silicone Molds
1. Cleaning & Flash Removal
• Peel off any flash around seams.
• Wash with warm soapy water.
• Use isopropyl alcohol for stubborn residue.
2. Trimming & Detailing
• Use sharp blades to clean edges.
• Trim pour spouts and air vents cleanly.

3. Surface Conditioning
• Apply mold release spray before casting.

Here I used cooking oil to apply on the mold

4. Inspection
• Check for air bubbles or tears.
• Ensure mold alignment and tight seams.
5. Test Cast
• Use a quick material like hot glue or clay.
• Evaluate detail capture and demolding.
6. Storage Tips
• Store flat and away from UV light.
• Avoid contact with sulfur-based materials.


Mold Ready for Casting
• Apply mold release before each casting
• Pour resin, wax, soap, or other materials, here I used epoxy in a ratio of 100:45g

• Allow curing before de-molding the final part


• The master piece and the Copy
  

Code file to test
Master model
Mold
3D print
Post process video