rapid prototyping - mold making

1)Rapid prototyping
-Create an .stl file that can be read by the rapid prototyping machine.
If you want to add a logo to your object, remember to make it no thicker than 0,4mm.

-When the piece has been created and retrieved, dip it (or brush it) with/in glue to harden the surface and make it generally stronger especially if the purpose is to create a mold.
(if this is the case, you might also want to consider making your piece with a wall thickness of at least 3mm to avoid breaking).
-Finally, you can sandpaper the object for a smoother surface (remember that whatever appears on your object will be in the mold).

2)Making the mold - first part
-You will now want to secure your object (double-sided tape) to a hard surface ("base-plate", ie: wood, plastic?..) and tilt it in order to later help the air and silicone flow.
-You will also have to create a hole in the base plate, so that air can flow out while vacuuming when the silicone will have been poured.
-Now, you can create small mounts/balls out of clay and place them asymmetrically around your object, these will create a negative space in the first part of your mold and enable the second part top to lock in easier when you want to reproduce your first piece.
- Finally, find a hollow object, tube or piece that you can wrap around your object, to create a wall which will prevent your silicone from leaking out.
(you can use the glue gun to secure it in place effectively)

-Now, all you need to do is prepare your mixture (mix the parts according to the instructions), and remember to use the vacuum to get rid of as many bubbles of air as possible (repeat this each time you prepare a mix to create rubber/silicone...).

 -Now pour in a slow, consistent way, until you have filled your mold and above your object....
It will now cure overnight.

2)Making the mold - second part
-Now that your first part is made, you can break your outer wall and release your piece (do not take your object out, as you will loosen your mold).

-Now the piece is released, turn it around and place it once again on a flat surface.
-Remember to put Vaseline onto the silicone parts which will be in contact with the second part of your mold (otherwise the second part will bond to the first when curing).
-Create a new "wall" around the upper part of your existing mold, and find two pieces (sticks, pencils;..) that you can stick against the walls of your object in order to create an air and pouring hole.

-(In my case I also placed a hollow object at the center of my piece in order to create enough space to retrieve the second part of the mold without damaging the original rapid prototyped object).
-Once you are ready - prepare the mixture again for the second part of the mold  - pour - again slowly - and wait (a night).

3)Making your final object - "reproducing the original"

-Now you have your two parts - you can easily put them back together with the locks you created in the first part of the mold making.
-Make two cones (out of paper) and place them subsequently in the air hole and pouring hole.
-Now prepare your final mix.
(remember that if you want to add colour to your mix, do it to before you mix the two parts together as there will not be much time to mix before the material starts to cure).
- Now, a final vacuum, and you are ready to pour, again in a slow and even way, until the material either starts to overflow, or starts coming up into your air hole.
-You can now either place a heavy object on top of you mold or tie it together with an elastic band in order to keep the two parts firmly in place.

-Voila - now, once again, just set back and wait for your final piece to cure.....