The keys for the keyboard

For the casting and molding assignment I made the twelve keys for the keyboard of my final project

Tehey have been made in white gesso using a silicone mold

The keyboard

The model

The first step has been to draw the model.

Model file

The key 3d model

Before starting ro make the mold I made a 3dprinted prototype

3d printed test

The mold

My first intention was to make a mold in two parts

3d drawings for the first mold

Then I've been suggested to take another way. So I prepared the drawings to make the mold for a silicone mold contining able to cast four pieces at a time.

Mold file

3d drawing for the definitive mold

The mold for the mold

Then I started to mill the mold to cast subsequently the silicone mold. This part of the work has been made in MDF.

Milling the MDF mold

As tool I used a 3mm end mill for rough path and a 3mm nose ball for the finishing path

Tools used

And this is the final result after milling

MDF mold

The silicone mold

Before pouring the silicone in the mold I prepared it with a spray stucco to get a smoother surface. At least I covered the surface with wax to make easier the remove silicone

Preparing the mold

Preparing the silicone

The silicone in the MDF mold

And at leat the silicone mold

Casting the keys

At least I started to pour the gesso in the mold

Pouring gesso

The final result

The keys after removing from the mold

The finishing