A. Using Rhino for design
B. Using Roland Modela Player 4
C. The Milling process
D. Molding

A. Using Rhino for design

I used the rhino for drawing the molding structure.

Firstly, I drew the outline of the face using illustrator, then I import the file into rhino to continue the drawing. Please click here for the video for producing the molding.

B. Using Roland Modela Player 4

Firstly, import the structure from rhino to the modela player 4

Choose modelling wax for the material.

Choose roughing first for the process.

Keep the cutting surface setting the same.

Select all for the cutting area.

Choose 3.18mm for the tool.

For path type choose, up cut.

For the cutting parameters, use 14 for the XY Speed.

Choose Finishing for the next process.

Keep the cutting surface the same.

Choose Partial for the cutting area.

Use 0.79mm for the tool

Choose Up Cut for the path type.

Choose 14 for the cutting parameters.

The following is the Model Setup.

The following is the Cutting-position Setup.

The following is the setting for modelling form.

After setting all the parameters, then press the processing for the cutting and a preview will appear afterwards.

C. Using Roland Machine for milling

First of all, I tried to mill with the foam first before the real milling with the wax.

The above shows the result of the foam after finishing the 'roughing'cutting.

After trying with the foam, then I milled it with the wax.

This is the finishing modelling of the wax.

C. Using Silicone for molding

The following chemicals are used for making the silicone, which is Formsil25 with catalyst.

Firstly, pour some water into the wax mold in order to know the amount of silicone that is needed and weight the water.Afterward, mix the part A with 5% of part B for at least 5 miniutes.

Then pour the mixture from a very high position to minimize as little air as possible.

Afterward, put the whole thing inside a vacuum condition and pump some air into it to make the bubble inside the silicone comes out. When the silicone nearly comes out of the level then let some air out, the level will drop again.Repeat this for a few times until all the bubbles come out.

Afterward, let it set and wait for 14 hours.

After taking the mold out from the wax, spray some baby powder before pouring the metal.

Heat the soft metal until it melts. The soft metal that is used is called Low Melt Fusible Bismuth Based Alloy Ingot.

Pour the liquified metal into the silicone mold. I faced the difficulty as it is hard to only fill the gap with metal as it is usually spread over. Therefore, i folded some aluminium foil surrounding the mold to prevent the spillage.

Wait for about 30 miniutes until the metal is cold, the shape is formed. Even though, it is not what i really expected, but it turns out to be quite good.

Please click here for downloading.