Assignment Requirements
Group assignment
- Review the safety data sheets for each of your molding and casting materials.
- Make and compare test casts with each of them.
- Compare printing vs milling molds.
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.
Progress Status
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Group page link + notes added.
Missing final photos and conclusions.
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Assignment Requirements
Learning outcomes
- Design appropriate objects within the limitations of your process.
- Demonstrate workflows used in mold design, construction and casting.
Have you answered these questions?
- Linked to the group assignment page and reflected on your individual page what you have learned.✅
- Reviewed the safety data sheets for each of your molding and casting materials, then made and compared test casts with each of them.✅.
- Documented how you designed and created your 3D mold, including machine settings.✅.
- Ensured your mold has smooth surface finish, that does not show the production process (by postprocessing if necessary).✅.
- Shown how you safely made your mold and cast the parts.✅.
- Described problems and how you fixed them.✅.
- Included your design files and ‘hero shot’ of the mold and the final object.✅.
Weekly planning
During the week, we carried out various activities that presented significant challenges but were also very rewarding, especially due to the opportunity to share and learn as a team. We met virtually with our colleagues at the node and participated in lab meetings, which allowed us to organize ourselves and conduct open workshops in different spaces. In these sessions, we reviewed and worked with input devices, understanding their operation and their importance in capturing data from the environment for subsequent processing in electronic systems.
During this week's group project, we conducted a series of experiments in molding and casting processes,
exploring various materials and manufacturing techniques. The objective was to understand the behavior
of different materials, as well as their applications in design and production.
We worked with a wide variety of materials, including: natural resin, bio-silicone, plaster, white cement,
two-component resin (A+B), silicone for molds, soy wax, glycerin for soap making, modeling clay, and chocolate base.
Each of these materials allowed us to analyze specific properties such as curing times, level of detail,
texture, strength, and surface finish.
Furthermore, the molds used in the processes were developed using digital manufacturing technologies,
including 3D printing and CNC machining. This allowed us to obtain precise geometries and adapt the designs
according to the requirements of each material.
Through this experience, we were able to compare industrial, natural, and biomaterials, evaluating their
advantages, limitations, and potential applications. This approach made it possible to integrate knowledge
of design, manufacturing, and sustainability, strengthening a more experimental and critical vision in
the use of materials.
A comparative analysis between 3D printed molds and CNC machined molds reveals significant differences
in terms of surface quality, level of detail, and post-processing requirements. These differences are
directly related to the fabrication method and the tools involved in each process.
In the case of 3D printed molds, the resolution is determined by the layer height, allowing
for the reproduction of fine and complex geometries. However, this layer-by-layer fabrication process
generates visible stratification, especially on curved surfaces. As a result, additional post-processing
steps such as sanding, coating, or resin finishing are often required to achieve a smooth surface.
On the other hand, CNC machined molds depend on the diameter and geometry of the cutting tool.
While extremely fine details may be limited by the tool size, the surface finish tends to be more uniform.
When using a ball-end mill, the toolpath marks are minimal and often nearly imperceptible, reducing the
need for extensive post-processing.
Overall, 3D printing offers greater flexibility in achieving intricate details and complex forms,
whereas CNC machining provides superior surface quality and precision with less finishing effort.
The choice between both methods depends on the design requirements, desired finish, and available resources.
Most of the materials used during the molding and casting exercises are supported by technical
data sheets provided by their manufacturers. These specifications are essential for understanding
material behavior, processing conditions, and performance in different applications.
As a representative example, the RTV Type 6 Silicone by Silika
is a room-temperature vulcanizing silicone designed for the fabrication of highly durable and
resistant molds. Its formulation offers a balance between flexibility, mechanical strength,
and ease of processing.
Due to its mechanical performance and ease of use, this silicone is particularly suitable
for creating flexible molds with complex geometries, enabling efficient demolding and
high-quality reproduction of fine details.
As part of the group assignment, a molding test was carried out using a
bio-silicone developed from accessible, nature-based ingredients.
The formulation was based on a biomaterial recipe obtained from a digital biomaterials platform.
The objective of this test was to evaluate the material’s behavior during preparation, pouring,
and solidification, as well as its surface finish and performance when cast into a 3D printed mold.
For this experiment, a group mold fabricated באמצעות 3D printing was used, featuring the shape of
a small Virgin figure with floral details. The mixture demonstrated good overall performance,
resulting in a visually satisfactory final piece.
Prior to preparation, the mold volume was measured using water to estimate the required material quantity.
The ingredients were then proportioned accordingly.
All components were placed in a metal container and heated to approximately 70 °C,
allowing them to melt and integrate into a homogeneous mixture. During this stage, continuous stirring
was essential to ensure uniform consistency.
Before pouring, a thin layer of petroleum jelly (vaseline) was applied inside the 3D printed mold
to act as a release agent. This step facilitated demolding and prevented damage to both the mold
and the final piece.
Once the mixture reached the desired consistency, it was carefully poured into the mold. The material
was then left undisturbed to cool and solidify.
During preparation, the bio-silicone exhibited good integration between its components, achieving
a uniform texture that could be poured without difficulty. The material adapted well to the mold
geometry, successfully reproducing fine details.
The final result was highly satisfactory, with an aesthetically pleasing surface finish. Despite
minor issues during heating, the material maintained its properties and performed effectively.
A challenge occurred during the heating stage, where part of the mixture adhered to the bottom
of the container. This was due to the use of a container that was too small and the application
of excessive initial heat.
To address this, the temperature was reduced and the mixture was stirred more consistently to prevent
further sticking or burning. The issue did not significantly affect the final outcome, as the material
continued to melt and retain its overall properties.
This experiment highlighted that, in biomaterials, not only the formulation but also the processing
conditions—such as temperature control, container size, and mixing technique—are critical for success.
Early-stage errors, such as overheating, can be mitigated through careful handling and process adjustment.
In conclusion, bio-silicone proved to be a valuable material for experimentation in molding and casting,
offering a sustainable alternative with satisfactory performance in both behavior and final appearance.
Plaster is a mineral-based material widely used in molding and casting processes due to its ease of use,
low cost, and ability to reproduce fine details. It is derived from calcium sulfate hemihydrate
(CaSO₄·½H₂O), which, when mixed with water, reacts and transforms into calcium sulfate dihydrate
(CaSO₄·2H₂O), forming a solid structure.
Plaster powder is activated by the addition of water, initiating an exothermic hydration reaction.
During this process, the material transitions from a fluid mixture to a rigid structure through the
formation of interlocking crystals.
This transformation is irreversible under normal conditions and allows the production of solid parts
with good dimensional stability.
Controlling the water-to-powder ratio is essential to determine the mechanical strength and porosity
of the final piece.
These characteristics make plaster suitable for decorative applications and prototyping, but limited
for structural uses.
From a regenerative design (regen) perspective, plaster can be combined with natural pigments and
organic fibers to explore new material possibilities. Although it is not biodegradable in the same
way as biomaterials, its low environmental impact and reusability in experimental processes make it
a relevant material for sustainable practices.
Water-based eco-resin is a mineral-based composite material supplied in powder form,
designed as a sustainable alternative to conventional synthetic resins. Its formulation
typically consists of modified gypsum or cementitious materials combined with polymer
additives that enhance mechanical properties and surface finish.
The material is activated by adding water at a recommended ratio of 3:1
(powder:water by weight). Upon mixing, a hydration reaction occurs, initiating
a crystallization process similar to plaster-based systems. This exothermic reaction
allows the progressive transition from a liquid suspension to a rigid solid structure.
Proper mixing technique is essential to ensure material homogeneity and to minimize
air bubbles, which can affect structural integrity and surface quality.
However, the material is relatively brittle under tensile stress and may require
reinforcement (e.g., natural fibers) for structural applications.
One of the main advantages of this material is its low environmental impact. Being
water-based and free from volatile organic compounds (VOCs), it is non-toxic and
suitable for indoor use without specialized ventilation. This makes it well aligned
with sustainable design practices.
Its compatibility with silicone molds and ability to incorporate both synthetic
and natural pigments make it especially suitable for experimental design processes.
Within a regenerative design (regen) framework, this material enables the integration
of locally sourced pigments and natural additives, promoting a more sustainable and
context-driven material culture. This approach supports the development of alternative
fabrication methodologies aligned with sustainability and circular economy principles.
Edible chocolate casting is a widely used process in food fabrication that allows the
replication of complex geometries using flexible molds, typically made of food-grade silicone.
This method is based on the controlled melting, tempering, and solidification of chocolate,
enabling high-detail reproduction and consistent surface finishes.
Chocolate is a composite material primarily composed of cocoa solids, cocoa butter, sugar,
and, in some cases, milk components. When heated, cocoa butter melts, transitioning the
chocolate from a solid to a liquid state. Upon controlled cooling, it recrystallizes, forming
a stable structure.
Proper tempering is essential to ensure the formation of stable cocoa butter crystals
(β-crystals), which determine the final appearance, texture, and gloss of the chocolate.
Temperature control is critical to avoid bloom (fat or sugar crystallization defects)
and to achieve a smooth and glossy finish.
In the context of digital fabrication and molding experimentation, chocolate serves as
an accessible and safe material to test mold geometries and evaluate surface quality.
Its ability to capture fine details makes it particularly useful for validating mold
designs before using more complex or permanent materials.
Soap casting using a glycerin-based melt-and-pour system is a widely accessible and controlled
fabrication process. It allows the production of customized solid soap forms through the melting,
modification, and solidification of a pre-formulated base. The use of food-grade or cosmetic-grade
silicone molds enables the replication of detailed geometries with minimal effort.
Glycerin soap base is a pre-saponified material composed of fatty acids, glycerin, and surfactants.
Unlike traditional cold-process soap making, no chemical reaction (saponification) occurs during
fabrication. Instead, the process involves a physical phase change from solid to liquid and back to solid.
When heated (typically between 60–75 °C), the soap base melts into a հեղuid state, allowing the
incorporation of additives such as colorants, fragrances, and exfoliants. Upon cooling, the material
solidifies while maintaining a uniform internal structure.
Temperature control is essential to prevent overheating, which may degrade the base or cause
evaporation of volatile additives such as fragrances.
Soap casting serves as an accessible entry point for exploring molding and casting processes.
Its low-risk handling and quick solidification time make it suitable for testing mold geometries,
evaluating surface finishes, and experimenting with additives in a controlled and safe manner.
Soy wax candle casting is a sustainable and accessible fabrication process that allows the creation
of decorative and functional objects through controlled melting and solidification. Soy wax, derived
from hydrogenated soybean oil, is a renewable and biodegradable material widely used as an alternative
to paraffin-based waxes.
Soy wax is composed primarily of vegetable-based lipids that transition from solid to liquid when heated.
This is a physical phase change process. Once melted, additives such as natural pigments, essential oils,
or fragrances can be incorporated. Upon cooling, the wax solidifies, forming a stable structure that retains
shape, color, and aroma.
Temperature control is essential to prevent overheating and to ensure proper fragrance retention and
a smooth surface finish.
Soy wax casting provides an effective platform for exploring sustainable materials and sensory design.
Its compatibility with silicone molds and natural additives makes it suitable for experimentation in
regenerative design practices and eco-friendly product development.
Throughout this week, the exploration of molding and casting processes allowed me to
understand the relationship between materials, techniques, and outcomes from a hands-on
and experimental perspective. Working with a wide range of materials—such as plaster,
eco-resin, bio-silicone, two-component resin, soy wax, soap base, and chocolate—helped me
recognize that each material behaves differently depending on its composition, processing
conditions, and interaction with molds.
One of the most valuable learnings was understanding that success in these processes does
not depend solely on following a recipe or technical data sheet, but also on controlling
variables such as temperature, proportions, timing, and mixing techniques. Small variations
in these parameters can significantly affect the final result, especially in terms of
surface quality, structural integrity, and detail reproduction.
Additionally, comparing digital fabrication methods such as 3D printing and CNC machining
allowed me to better evaluate how mold-making technologies influence the final outcome.
I learned that while 3D printing enables more complex geometries, CNC machining offers
superior surface finishes with less post-processing, highlighting the importance of
selecting the appropriate method based on design requirements.
From a sustainability perspective, experimenting with biomaterials—particularly bio-silicone
and natural pigments—was especially meaningful. It allowed me to connect fabrication processes
with environmental awareness and regenerative design principles. I realized the potential of
integrating locally sourced materials and natural resources into design workflows, promoting
more responsible and context-driven practices.
Finally, this experience reinforced the importance of experimentation, iteration, and
problem-solving. Challenges encountered during the process, such as material overheating
or mixing inconsistencies, became learning opportunities that improved my understanding
of material behavior. Overall, this week strengthened my ability to critically evaluate
materials and processes, and to approach design and fabrication with a more informed,
sustainable, and experimental mindset.
In the individual component of this assignment, I integrated knowledge from previous weeks
with new experimentation in biomaterials and molding processes. A key aspect of my work was
the incorporation of biomaterials and natural pigments inspired by native communities,
exploring their potential within a sustainable and context-driven design approach.
Additionally, I utilized molds developed through CNC machining, combining digital fabrication
techniques with manual processes. This allowed me to better understand how different fabrication
methods influence the final outcome of the pieces.
I also applied knowledge acquired in previous weeks, particularly in 3D scanning and digital
modeling. As part of this process, I scanned a traditional Torito de Pucará using a
mobile scanning application. The resulting digital model was then processed in
Ultimaker Cura to prepare it for 3D printing.
Once printed, the object was used as a base model to create a silicone mold. This workflow
enabled the transition from a digital representation to a physical mold, which could then
be used in subsequent casting processes with different materials.
Overall, this experience allowed me to connect digital fabrication tools, traditional cultural
references, and biomaterial experimentation into a cohesive workflow, reinforcing a more
integrated and multidisciplinary approach to design and production.
In this stage of my individual work, I applied a complete workflow that integrates
digital fabrication and material experimentation. The process began with the 3D scanning
of an object, followed by digital preparation and 3D printing, which enabled the creation
of a master model for mold fabrication.
Using the printed model, a silicone mold was produced by mixing silicone
with its corresponding catalyst. The mixture was poured over the model inside a container,
allowing it to cure and form a flexible negative mold capable of capturing fine details.
After obtaining the silicone mold, it was used to produce a candle using soy wax,
incorporating a citrus fruit extract and natural oils to enhance the sensory properties of the final piece.
The silicone mold demonstrated excellent flexibility and detail reproduction, allowing for
an accurate transfer of the original geometry. The soy wax performed well during casting,
achieving a smooth finish and effectively retaining the added aroma.
The integration of digital fabrication tools with traditional casting techniques enabled a
complete workflow from digital model to final product, reinforcing the relationship between
design, materials, and fabrication processes.
This experience highlights the versatility of silicone molds and soy wax as accessible materials
for prototyping and product development. It also demonstrates how combining digital tools with
natural materials can lead to innovative and sustainable design outcomes.
As part of my individual work, I developed an experimental biomaterial using
coffee grounds (coffee waste) as the main component. The objective
was to explore the potential of organic waste as a sustainable material for molding
and fabrication processes, while also evaluating its physical behavior under controlled conditions.
This experiment was complemented by the use of an electronic system developed in previous weeks,
consisting of a temperature and humidity sensor connected to a microcontroller. This setup allowed
real-time monitoring of environmental conditions during the drying and curing process of the biomaterial.
The coffee-based biomaterial is formed by combining organic particles with a binding agent,
creating a composite structure. The binder acts as a matrix that holds the coffee particles together
during drying. As water evaporates, the material transitions from a malleable mixture to a rigid or
semi-rigid structure, depending on the formulation.
To better understand the behavior of the biomaterial during the drying phase, a temperature
and humidity sensor was used. The sensor was connected to a custom electronic board, allowing
the collection of environmental data in real time.
Monitoring these variables helped identify how temperature and humidity influence drying time,
material shrinkage, and final consistency. This integration of digital tools with biomaterial
experimentation provided a more analytical and data-driven approach.
The coffee-based biomaterial showed good cohesion when properly mixed with the binder. However,
drying conditions significantly affected the final result. High humidity slowed down the curing
process, while controlled environments improved consistency and structural integrity.
The entire process, including formulation, environmental data, and results, was documented using
the Regen Bio platform. This digital tool supports the structured development and sharing of
biomaterial recipes and experimental data.
This experiment demonstrated the potential of organic waste such as coffee grounds as a viable
material for sustainable design. Additionally, integrating electronic sensors allowed for a deeper
understanding of environmental influence on material behavior, bridging digital fabrication,
biomaterials, and data-driven experimentation.
Throughout this week, I developed a deeper understanding of molding and casting processes
by combining digital fabrication tools with hands-on material experimentation. Working with
different materials such as bio-silicone, eco-resin, plaster, soy wax, soap, chocolate, and
coffee-based biomaterials allowed me to explore how each one behaves under different conditions
and how their properties influence the final outcome.
One of the most valuable aspects of this experience was integrating knowledge from previous weeks.
The use of 3D scanning, modeling, and printing enabled me to transform a physical object into a
digital file and then back into a physical mold through silicone casting. This workflow helped me
understand the full cycle from digital design to material production.
Additionally, incorporating biomaterials and natural pigments inspired by native communities
gave a new dimension to my work. It allowed me to reflect on the importance of sustainability
and the potential of using local resources in design processes. I realized that materials are
not only technical elements but also cultural and environmental expressions.
The use of my electronic board with temperature and humidity sensors added a data-driven layer
to the experimentation. Monitoring environmental conditions helped me better understand how
variables such as heat and moisture affect the behavior and curing of biomaterials.
I also learned that mistakes are part of the process. Issues such as overheating, incorrect
proportions, or material inconsistencies became opportunities to improve my understanding
and refine my techniques. This reinforced the importance of patience, observation, and iteration.
Overall, this week strengthened my ability to connect design, technology, and sustainability.
It encouraged me to think more critically about material choices and to approach fabrication
as an experimental and learning-driven process. This experience has motivated me to continue
exploring biomaterials and integrating them into future projects.
Gruop Work- Group work- Molding and casting
Comparison: 3D Printed vs CNC Machined Molds
Technical Specifications: RTV Silicone Type 6 (Silika)
Key Properties
Processing Parameters
Mechanical Characteristics
Packaging and Storage
Biomaterial Test: Bio-Silicone
Materials and Quantities
Material Properties and Functions
Ingredient
Quantity
Function
Observed Characteristics
Handling Considerations
Colapiz
520 g
Main structural base
Softens when heated and solidifies into a flexible structure
Heat carefully to avoid sticking or burning
Water
500 ml
Solvent and binder
Facilitates homogenization of the mixture
Maintain correct ratio to control viscosity
Glycerin
50 ml
Plasticizer
Improves flexibility and prevents brittleness
Mix thoroughly for uniform consistency
Clove oil
15 drops
Aromatic additive and natural preservative
Provides scent and delays fungal growth
Use in small quantities; add at controlled stage
Fabrication Process
Observations
Challenges and Solutions
Reflection
Technical Characterization of Plaster in Molding and Casting Processes
Material Composition and Reaction Mechanism
Processing Parameters
Fabrication Process
Mechanical and Physical Properties
Environmental and Safety Considerations
Applications in Design and Fabrication
Integration with Regenerative Practices
Technical Characterization of Water-Based Eco-Resin
Material Composition and Reaction Mechanism
Processing Parameters
Mechanical and Physical Properties
Environmental and Safety Considerations
Applications in Design and Fabrication
Integration with Regenerative Practices
Technical Characterization of Edible Chocolate Casting Using Silicone Molds
Material Composition and Transformation Mechanism
Processing Parameters
Fabrication Process
Physical and Sensory Properties
Safety and Hygiene Considerations
Applications in Design and Fabrication
Integration with Experimental Practices
Technical Characterization of Soap Casting Using Glycerin Base and Silicone Molds
Material Composition and Transformation Mechanism
Processing Parameters
Fabrication Process
Physical and Sensory Properties
Safety and Handling Considerations
Applications in Design and Fabrication
Integration with Experimental Practices
Technical Characterization of Soy Wax Candle Casting Using Silicone Molds
Material Composition and Transformation Mechanism
Processing Parameters
Fabrication Process
Physical and Sensory Properties
Safety and Handling Considerations
Applications in Design and Fabrication
Integration with Experimental Practices
Personal Reflection
Individual Task
Silicone Mold and Soy Wax Candle Casting
Silicone Mold Fabrication
Soy Wax Candle Casting Process
Observations
Conclusion
Biomaterial Experiment: Coffee Waste Composite
Materials Used
Material Composition and Mechanism
Fabrication Process
Sensor Integration and Monitoring
Observations
Platform Documentation
Reflection
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