A new mold production process

A mold for the woofer is currently being developed. The mold for the satellite prototype was based on a master positive and was made by pouring plaster onto it using clay molds. This is a one-time process that results in a single mold and is a lot of work.

To be able to repeatedly cast molds, I started printing mold sections and casting them in condensation silicone. To ensure a sturdy mold, I designed a formwork for each section that guarantees a consistent silicone wall thickness. This saves significant amounts of silicone and also allows for better dimensioning of the plaster mold.

The mold parts come out of the printer and are post-processed with sandpaper, filler and spray filler and then sanded again.

The top of the mold is over 30 cm, which is printed on a new Neptune 4 Plus, while the smaller parts are printed on the Ender 3 V3 SE. The "lid" is also too large for the Ender. This larger printer makes a huge difference, because otherwise I would have had to print these parts in four pieces and then glue them together. Due to slight deformations on the underside of the print, it's always difficult to maintain accuracy.

The silicone needs about a day to harden. Plaster hardens in 30 meters. Then it warms up, and I remove the rubber and plaster from the formwork to protect it from the heat and prevent warping.