3D Modeling for Chocolate Casting Project

Here is my 3D chocolate mold for my 3D project!!!

1. Fusion 360
2. 3D Printer
3. Chocolate
4. Casing

I started by sketching the star-shaped design I wanted, planning for an extruded star. I drew the profile and noted all key measurements, so when I moved into Fusion 360 I could use those dimensions as parametric constraints to guide the model.

For the design stage, I worked entirely in Fusion 360. I started by setting parameters so the model would stay within the correct size range, setting both the length and height to 25 mm. Then, I created a construction line 25 mm tall as a reference. From the top of that line, I used a 26-degree angle to draw two shorter lines extending outward and connected them back to the base point of the construction line, forming the first section of the star. Using the Circular Pattern shortcut, I selected a center point and repeated this shape five times to complete the star outline. After that, I cleaned up the sketch by erasing all the inner lines, leaving only the star shape.

Next, I extruded the star 25 mm while applying a -30 degree taper to create angled sides. To ensure the design would release properly when used as a mold, I finished by running a draft analysis.

After finishing the design, I exported the file to the Makerspace 3D printing queue. I placed the model on the print bed in the slicing software, double-checked the orientation, and adjusted the settings to ensure everything was correct for printing. Once the slicing was complete, I confirmed that all of the software parameters were set properly. Finally, I selected a printer from the available options and submitted my file into the queue for fabrication.

I then picked it up from the Makerspace once it was printed and was ready to bring to class to be cast.

Next, I brought my 3D print into class to create the silicone mold. When I arrived, I noticed that the bottom of my model was slightly too large for the casting box. To fix this, I carefully trimmed down the sides until it fit, though I worried the silicone might still seep into the interior. To be safe, I borrowed a classmate’s extra mold while also continuing with mine. I glued my prints securely to the bottom of the casting container, then mixed the silicone according to instructions. After pouring it in, I gently tapped the container to release any trapped air bubbles and left the mold to cure.

The next day, I removed the silicone casting along with my 3D prints to reveal the finished molds. My original print turned out fairly well, though it had quite a few air bubbles throughout. The other mold came out really clean, but it was much harder to remove the print from the silicone. Once both molds were freed, I prepared the chocolate and carefully poured it into each mold. This was the final step in transforming my digital design into a functional chocolate mold, ready to be tested.

I connected this project very closely to the reading we were assigned for this week. The reading for 4.2 Molding and Casting pointed out the significance of taking into account both the design decisions allowing clean exit and the physical characteristics of the materials. When I tapered my star mold and used draft analysis to ensure that the chocolate could actually come out, I had a firsthand experience with this. This demonstrated to me that design must take into account the realities of fabrication and is not just digital. I was also interested in section 5.2. I moved between sketches, Illustrator files, Fusion models, and even mental pictures of how the mold would come together throughout my process. Together, these representations enabled me to troubleshoot and proceed, but none of them provided me with the whole picture on their own. In section 6.1, I found that parametric design should help the analysis of geometry, machine settings, material behavior, and interdependencies. Between the Three was a perfect reflection of what I had discovered. This relates ot last week's project, where I observed the interactions between geometry, material thickness, and machine kerf by adjusting parameters and experimenting with various angles. When cutting and assembling, even minor changes made in Fusion or Illustrator produced physical results. All things considered, the reading made it clearer to me that design is not just about creating a form but also about managing relationships and uncertainty.