Some of you might think this is interesting. I've started working on the casting blocks for my completed parts and started with the body. The process works like this:
- You need to figure out how you want to split the model. In this case there is no splitting required, each part can easily be cast as one piece. But models with complex shapes or poses usually need to be broken into more than one part with some kind of indexing feature for assembly (peg/slot, etc).
- Each part is going to be using a two-part mold so you need to figure out where you want the mold line to be. Determine that line and create it on the model, choosing a spot that will be easy to clean and won't disrupt important details if you end up having flashing.
- Once you know where the line is you need to figure out what angle, if any, there should be between the part's surface and the interface of the two molds. This is particularly important if you are interfacing on a hard edge on a mechanical object; you don't want to be overly biased to one side or the other because it can potentially make mold slippage easier.
- After the interface surface around the object is determined you need to merge that with the block's outer perimeter. If your interface surface is simple then this step is relatively trivial. With something more complex it can be tricky to get things to flatten out in a smooth manner.
Here's a picture of a complex mold surface (the sprue hasn't been added yet, just the raw interface) where the part itself is in green and the mating surfaces in grey:
EDIT: Figured I'd just edit instead of cluttering up the thread with a new post. Here's a completed set of blocks with locating nubs and sprue added in. The sprue is setup so that I have the option of doing a bottom-injection style instead of pour style. The advantage of injecting from the bottom is that it fills from the bottom instead of running down the sides and pooling. Theoretically this helps avoid having bubbles/voids in the cast because the air can evacuate out the top without having to compete with resin trying to enter through the same sprue trees.
EDIT2: Huh...that...doesn't look right...OH SHIT. Yup, that's fucked. I've got multiple major errors in there. See if you can figure out how I fucked it up.
EDIT3: Jesus, it took me like five tries to get this all sorted out. Think I've FINALLY got everything pointed in the right direction.