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CURB WAX
A client on a low budget requested a mold for repeatable wax pours to start up their new product line of curb wax
DESIGN PROCESS
The client approached me with a request to create a mold based off of a single drawing and a CAD model that was supplied by a Fiverr contractor. I immediately let the client know that the supplied 3D model would not be sufficient for the robust and repeatable mold that they were hoping for.
I offered to rework the clients design and create their repeatable mold, going through the process from start to finish. There was much discussion on how the design would be translated from a 2D drawing to the final 3D product.
I sat down with the client and we reviewed examples of previous products on the web before coming together on a final design.
MOLD MAKING PROCESS
The mold was created in three separate steps:
1. 3D print a negative mold for casting
2. Create a positive cast of the mold in plaster
3. Make a final negative cast in silicone
The design was created with repeatability and ease of separation between the cast and mold in mind. The walls of the mold are drafted outward. Without the draft, the mold may prevent the cast from ejecting properly and cause uneven or broken surface finishes.
Originally, the client simply asked for a 3D printed mold. The issue lies with material adhesion between wax and plastic. The wax cast would most likely adhere to the individual layer lines and textured surfaces within the 3D printed mold leading to difficulty in the removal process. This can lead to a high number of failed casts. Additionally, the hot wax would potentially melt and warp the 3D printed mold over time. This was not a sustainable option.
The solution was to cast the 3D printed mold with plaster, followed by a negative mold in a two-part silicone mixture. The silicone mold allows for repeatable castings and an easy removal process. Silicone can be flexible while maintaining high relief. It is able to withstand the repeated thermal changes without degradation. This was the best option for the client.
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