Modeling

       -while modeling i came up with more than one design, most of them were too complex to be exported as a STL I tried more
than one shape, square, triangle, rectangle and finally i came up with an idea, to simplify the connections between the shapes
makes it easier for rhino to recognize

 


                                                   
By trimming the meshes it gave me a more dynamic shape. also i tried to boleen them, group by group till finally rhino managed to
union them all
This box sounding the design is the Wax mold I'm milling my design in. Actually after starting to mill i though that if the outline of the
mold was circular like that of the design, it would've saved time and material

TIP Take your time to modify your design to save as much as you can, TIME AND MONEY

Milling
       I used the IModela to mill the design in wax. Before exporting your design from rhino as a STL Make Sure it's LEFT TOP point is at
the origin (0,0,0) as the machine starts working from top to bottom and from left to right and also make sure its in millimeters other
wise the machine wouldn't recognize it

The Machine mill STLs on two stages, ROUGH and FINAL where the
Rough uses the bold pin, and it takes less time than the final, it also
 moves on both axis (x,y) at the same time. While the FINAL, uses a
 finer pin to smoother the contours of your design, it will take much
more time than the first one, since it mill your design twice on as
straight lines in the direction, then the second is doing the same
thing but in the X direction. Both procedures with variations of the Z
 direction according to your design's surface
t

i had an in individual problem with the mold is that i was using a
used wax bar so the borders of my design overlapped the old
design milled in the bar. i had to fill the opening with tape
 ! let's hope it works 

Cooking

Finally i did the mixture
of the rubber mold and
poured it in the wax, it
still has six hours
to go!

IN 20 MINS
After finishing the mold you take it off the wax, you then get the negative of your design. Then you mix the solution for your
final piece. you should use same amount from both jars and mix them together then pour it to your rubber mold, but by
changing the ratio between the two solution you can control how hard or flexible your final piece will be