Moldmaking and Silicone Casting Process

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For prototype builds of new brewers, many 3D printed components from a variety of build processes are used. 3D printing, as an industry, does not have many good solutions for making novel gasket designs. You can print in “rubber simulate” materials with Polyjet and SLA, but these materials tend to break down when subjected to higher temperatures, pressures, and chemical solvents. Additionally, these materials are not food-contact safe.

As it turns out, 3D printing, specifically Polyjet, is perfect for making mold halves.

Polyjet materials provide an accurate, rigid support for a variety of silicone durometers during the setting process. There are a lot more materials available from casting manufacturers like Smooth-On that reach different durometers, food-safety requirements, and thermal properties.

I helped to develop this technique into a standardized, cheap, quick-turn-around request process for engineers at my company looking to make gasket prototypes.

References: https://www.fictiv.com/blog/posts/tips-for-prototyping-food-safe-products . Fictiv is a great source of information for all things prototyping and manufacturing.

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