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3D Printing for Silicone

Molding
INTRO

Currently among all the 3D printing technologies FDM is the

most commonly used technology for the prototyping. We can
use 3D printing for making 2-3 parts but if we want to make a
small quantity production of 15-20 parts then 3D printing
would be a costly and time consuming task.
Thus for reducing the cost and time for small scale production
a suitable option Is silicone moulding.

OVERVIEW

Component made using urethane casting

in a silicone mold

Silicone moulding also known as room temperature vulcanizing (RTV) moulding creates finished
products for prototyping, functional testing and short-run production. Considering tool life and cycle
times, it is ideal for small quantities (15 - 60 castings) because it offers lead times and costs that are well
below that of machining or injection moulding.

Silicone moulds are made by pouring silicone rubber over a pattern. After curing, the resulting firm but
flexible mould can produce parts with extremely complex geometry, intricate detail and tight tolerances.
The parts are cast from a silicone mould made with thermoset materials (commonly urethanes) that are
available with a vast array of mechanical, thermal and electrical properties.

Silicone Mould and Casted Part

Image Courtesy: https://www.etsy.com

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The traditional silicone mould-making process uses a machined pattern made of plastic, wood or other
materials. This method is often expensive and time consuming, and as pattern complexity rises, lead
time and cost also increase.

SLA and FDM - 3D printing technologies are an innovative alternative to machining patterns for silicone
mould making. These are built by laying patterns layer by layer, using data from computer-aided design
(CAD) files. Pattern generated with these process require post processing for getting smooth surfaces.

REQUIREMENT FOR SILICONE MOULDING

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Master part or 3D printed model of master part used as pattern

3D printed mold box
Mould Release
Silicone Rubber Material
Latex Gloves and protective glasses
Surgical blade
Container for preparing the silicone mixture
Fasteners for holding the mould box

STEPS FOR CREATING SILICONE MOULD

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3D printing of master part

Sanding, Polishing and cleaning of master part for smooth surface
Volume calculation for mold box, silicone mixture and Urethane casting material
Designing and printing of mold box
Placement of master part in the mould box
Adding Sprue
Mix and pour silicone
Mold Complete

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CAD DESIGNS AND 3D PRINTING OF MOLD BOX

The purpose of a mold box is to contain the liquid rubber (after it is poured over and around a model)
until the liquid turns to a solid.
Mold Box

3D printed mold Box

PLACEMENT OF MASTER PART IN MOLD BOX

The master pattern is placed in such a way that it makes no contact with the mould box. Suitable
spacers are inserted in a way so as to not interfere with the cast part.

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ADDING THE SPRUE

We create a sprue or sprues on our part. These will become funnel shaped holes in the mold. We need
them so we can get our casting material into the mold.
Keep in mind when we are molding a part, if something looks like it will trap bubbles, try to orient things
to avoid it. Our goal is to create a mold that will produce the best quality parts with the least amount of
work and fiddling.

MIX AND POUR SILICONE

Initially put mold release over the master part and the inner surface of mold box which held in easy demolding.
Combine equal amount of liquid part A and B (1A:1B) of silicone rubber material and mix these liquid rubber
contents thoroughly. Pour this mixture over prepared model and let it cure to a solid, flexible rubber mold.
After that demold it to get mold cavity that further used for casting the duplicates of the master part.

Mold Box after Pouring the Silicone Rubber Mixture

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Demolding

REFERENCES

1. http://www.stratasys.com/~/media/Main/Secure/Applications/RTV%20Molding/PolyJet/SSYSTA
GSiliconeMolding%202314%20FINAL.pdf
2. http://www.instructables.com/id/Two-Part-Silicone-Casting/?ALLSTEPS