During this week, we learned the complete workflow of molding and casting, from the digital design of molds to the fabrication of physical parts using different materials. We explored how to design positive and negative geometries, prepare molds for manufacturing, and understand the behavior of casting materials during the curing process.
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The molding and casting process enables the creation of objects through reusable molds into which liquid materials are poured and later solidified. This technique is commonly used for the fabrication of decorative pieces, prototypes, and customized objects with complex geometries.
In this practice, we manufactured a decorative sculpture-shaped candle. First, we produced a silicone mold from a 3D-printed model, using a PLA counter-mold to ensure stability during the molding process. Subsequently, paraffin wax was used to obtain the final casted candle.
To begin the process, we selected and prepared the sculpture design for manufacturing. The model was produced using 3D printing and later sanded to improve the surface finish and eliminate minor printing imperfections.
Next, we designed and printed a PLA counter-mold to provide structural support during silicone casting. The silicone rubber mixture was prepared according to the manufacturer's specifications, including the appropriate catalyst ratio.
The printed sculpture was carefully aligned inside the counter-mold, and the silicone mixture was poured around the piece. To improve the final quality of the mold, we used a vacuum pump to remove trapped air bubbles before curing.
After complete solidification, the original model was removed, resulting in a flexible silicone mold capable of reproducing the geometry accurately.
For the casting stage, paraffin wax was melted and poured into the mold after positioning the wick at its center. Once cooled and solidified, the final candle was demolded and inspected.
We successfully obtained a silicone mold and a decorative sculpture-shaped candle. The final piece presented good geometric definition and preserved the main characteristics of the original digital model. The use of the vacuum pump significantly improved the mold quality by minimizing air bubbles and surface defects.
During this assignment, we learned the complete workflow of molding and casting, from digital design and 3D printing to mold fabrication and final material casting. We explored how different materials behave during curing and solidification, as well as the importance of mold preparation and quality control.
We also discovered how molding techniques allow the replication of complex geometries while offering great freedom for material experimentation. The same mold can be used with different materials such as wax, resin, silicone, plaster, or composite mixtures, making this process highly versatile for prototyping and product development.
This practice enabled us to fabricate a customized mold capable of reproducing complex shapes with good accuracy. The use of the vacuum pump improved mold quality by eliminating air bubbles, while the molding and casting workflow demonstrated how digital fabrication can be combined with traditional manufacturing techniques to obtain high-quality physical objects.
From the perspective of my final project, this technique could become one of the main fabrication methods for producing the tactile pieces intended for children. Molding and casting allow experimentation with materials such as resin, wax, and customized mixtures, while also enabling the incorporation of recycled fragments, colors, glitter, textures, and other sensory elements that can enrich children's interaction with the project.
From my professional perspective in architectural education, this assignment was particularly interesting. Physical model making is frequently used during the first semesters of architecture programs; however, molds are traditionally produced through manual techniques. This workflow opens new possibilities for integrating digital fabrication technologies into introductory design courses, allowing students to connect design, prototyping, material experimentation, and manufacturing within a single process.