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8. Moulding and casting

Group Assignment

In the group assignment, we were assigned to test and evaluate various materials for their effectiveness in molding and casting. Me specific focus was on Standard Plaster, which I researched and experimented with extensively. Other collegues worked on other materials.

you can find more about each material and the results here

Individual Assignment

For the individual assignment, we had to design a mold around the process you'll be using, produce it with a smooth surface finish, that does not show the production process, and use it to cast parts.



Designing Process

My idea was to design and create my teaching account logo as a keychain, so I started designing it in Fusion 360 .



After finshing I exported it as a stl file.





Machine Settings

  • The Software used is SRP Player which is to have a view on what will the end result be.
  • After uploading the STL file, the software provided a clear preview of the design, with step-by-step instructions on the left-hand side.
  • The preview provided by SRP Player included dimensions of the design, ensuring that the final product was accurate and met the necessary specifications.


  • When working with the SRP Player software, I had the option to choose the type of milling needed for the project. I opted for a better surface finish rather than faster cutting time, as there were certain details that I wanted to be visible in the final product.
    Additionally, I had to consider whether the design had curved surfaces, which was the case with my design. This required careful attention to the milling process, as curved surfaces can be more challenging to mill accurately.


  • After selecting the appropriate milling options in SRP Player, the software automatically generates the tool path. This allows for accurate milling of the design and ensures that the final product meets the necessary specifications.



  • Then, SRP Player provides a preview of the final product and estimates the cutting time required for milling, But it shows some errors .





  • I then went back and changed the tool path, I chose a 3/32” Square tool for roughing and a 1/16” Ball tool for finishing to achieve the desired level of accuracy and detail in the final product.



  • The milling machine used is Roland SR-20, and here is the path amd the tool list needed.



  • Establishing the origin of the wax



  • Once the roughing process is complete, a notification will prompt the user to switch to the finishing drill bit.



  • The end product was remarkable, with clear details and smooth curves.



    • Silicone Moulding

  • To create the mold, I utilized silicone, beginning by measuring out equal quantities from each container.




  • After measuring out the equal amounts of silicone, I mixed them together and poured the mixture carefully into the mold.



  • After waiting for approximately 24 hours, the final result is revealed, as shown.




    • Casting with Resin

  • To begin, measure out a 10A:6B ratio of resin A and hardener B.( 21.9:13.2)




  • Once the resin and hardener have been measured, they are mixed together thoroughly before adding glitter to the mixture.


  • After adding the glitter to the resin mixture, it is poured into the mold for casting.



    • Final Results

  • After allowing for 48 hours of curing time, the final result is revealed, as follows.




  • I had extra Resin so I put it into on of the collegues mold and here is the final result.



    • Last update: September 12, 2024