Replicate entire 3D taiyaki with your own 3D molds! The most common and representative method in vacuum forming technology is to place the object to be molded on a workbench, press down a heated and softened vacuum forming sheet, transfer the shape at high temperature, and then cool and fix it on the bottom of the workbench. Usually, the finished mold will have a "flat cross-section on one side." Today, we'll introduce a slightly different method! With a 3D two-part mold, you can easily demold a complete fish in just 4 steps. Let's take a look at how to reproduce the other half of the taiyaki body:
Two-part molds allow you to replicate complex 3D works. Not only do they solve various design constraints, but they also allow you to create finished products by simply pouring materials like food, plastic, or clay into the mold, then cooling and solidifying them. You can even create hollow shapes! This method also reduces material usage and keeps your workspace clean, as materials are injected into two sealed upper and lower molds.
When replicating a 3D model using vacuum forming technology, the mold design method differs slightly from traditional methods. First, you need to decide "how to divide the model." This step is especially crucial when creating asymmetrical shapes! Taking taiyaki as an example, there are two ways to create the cross-section.
Taiyaki has a perfectly symmetrical shape, and its curved and rounded design is well-suited for vacuum forming. Therefore, splitting it horizontally is the most successful design approach. Once you've decided on the cross-section direction, use 3D modeling software to design the taiyaki cross-section model! (Also check out: 3 Free 3D Modeling Software Options! Easy Design for Beginners)
As we've mentioned before, models with "rounded curves" are better suited for vacuum forming than "right-angle" shapes (Also check out: 3 Vacuum Forming Tips! Further Improve Blister Packaging Quality). When pressing down the sheet during vacuum forming, the heated material sheet instantly contacts the rounded corners and tightly wraps around the entire object along the curves. This results in a high-quality mold with a smooth and beautiful surface.
For models to be vacuum formed, avoid right angles, sharp corners, and deep indentations as much as possible. Adding curves and slopes between the taiyaki scales will significantly increase the success rate of vacuum suction. It will also allow for smooth and easy demolding after forming and cooling!
By designing small holes in the main body of the model, any air trapped between the material sheet and the model can be smoothly expelled through the air vents at the moment of vacuum suction. This improves adhesion during molding, and better airflow leads to more precise detail in vacuum forming!
For the taiyaki mold, design holes of about 1-2mm at the corners between the scales. This allows air trapped in small gaps to be easily expelled during vacuum forming, completing the model design!
The two molds (top and bottom) are firmly secured after injecting materials like chocolate. To completely seal the unhardened material, design a 6mm wide, 2mm deep securing area around the bottom perimeter of the model using 3D modeling software. This ensures a tight seal for the material and prevents leaks until the chocolate hardens.
Even if the shape you're making changes each time, keeping the above four points in mind when designing your model will be fine. Afterwards, use FDM 3D printing (e.g., Ultimaker, Prusa 3D printers, etc.) and a heat-resistant 3D printer filament like PETG to produce your model.
Finally, set the 3D printed small taiyaki model into the FormBox vacuum forming machine and combine it with a transparent vacuum forming sheet. Once the sheet softens, simply press it down for instant vacuum suction and forming, and one mold is completed in just 3-5 seconds!
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With the FormBox vacuum forming machine, you can rapidly replicate over 10 molds using a single model in under an hour. If you're tired of traditional molds, you can now become your own mold maker! Reduce mass production costs, research and bring your original designs to life, and create your own desktop sweets workshop!