Key Design Considerations

I thought about the post processing and preparation required to create molds and cast my knife handle design. Based off of my design, I determined a two part mold was best, with the seam close to the middle of the handle, and the pour spout for the casting resin to be at the flat top of the handle. This would allow the seam to be easily sanded and not obstructive. The pour spout was placed on a flat portion of the handle, so it can easily be sanded down as well.

Process Overview

We took the clay model and embedded it in a different kind of clay. This clay did not dry or harden, making it a great medium to hold the place of the second half of the mold while the first part of the mold was poured. The silicon used to make the molds was Mold Max 29NV from the brand Smooth-On.

A foam core box was made with about .75 inches of spaces in all directions away from the handle. This box will hold the silicon as it cures to create both parts of the mold.