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14.Molding and Casting

🧪 Fab Academy — Week 14: Molding and Casting

👋 Introduction

In this week’s assignment, I explored the process of molding and casting using 3D printed forms and casting materials. I designed and fabricated my own silicone molds, created casts using gypsum and epoxy, and even made chess pieces.

🧰 Materials Used

  • 3D printer: Bambu Lab
  • Design tool: Fusion 360
  • Resins: Kristall epoxy (Part A & B)
  • Gypsum powder
  • Pigment / Colorants
  • Silicone for mold
  • Molding box (PLA)
  • Object to replicate: Pig figure, cartoon face, etc.

🖥️ CAD Design

Model designed in Fusion 360 for the mold structure.

CAD Design Mold Close-Up

🖨️ 3D Printing

The mold box was printed using Bambu Lab 3D printer.

Printing Process Mold Box

🧪 Resin Preparation

Mixing two-part epoxy:
Epoxy A
Epoxy B

🧼 Mold Making & Casting

Pouring resin into molds:

Red Mold
Blue Mold

Cast using powder material:

Powder
Piggy Toy
Face Cast

🐷 Pig Model Casting

Front and back results:

Front
Back

♟ Chess Set with Resin

I experimented with transparent resin to make a chess set:

Chess Board

🖼️ Additional Molds and 3D Designs

Other shapes and plaster work:

More Mold Work
Another Mold

🧑‍🔬 Reflections

Learned how to mix resin properly
Practiced designing for molding and casting
Experimented with epoxy and gypsum
Developed full fabrication workflow: design → print → cast

🙋‍♂️ Author

Yryszhan Sansyzbay
Fab Academy 2025
Email me