Boomerang Cast

The goal of this project was to practice production level prototyping by making a silicon mold and acrylic resin casts with this mold. For this project, I will be adding clay embellishments to a wooden boomerang. 

Final Products

Silicon Mold-Making

I then traced the shape of the boomerang onto a sheet of foam core and used it to construct a box around it with foam core and hot glue.

I then used hot glue to seal the edges to prevent leaks while the mold sets.

Next, I hot glued the boomerang to the bottom of the box, making sure it was as flat as possible. I also used Mod Podge to seal the clay embellishments.

I used SuperSeal™ Sealing Agent to seal the porous clay and wood (so the silicon will not soak in) and let it dry for 1 hour. Next, I used Ease Release™ Release Agent to ensure the silicon will peel off easily when the mold is finished setting.

To pour the mold, I mixed equal volume parts of Part A and Part B of the OOMOO™ Silicon Mold-Making Kit together and mixed them thoroughly.

I poured the silicon mixture into the box until it was filled and waited 6 hours for it to cure fully.

Once the mold was cured, I peeled the foam core box off. It appeared as though some of the silicon had leaked underneath the boomerang, so I used a utility knife to cut away the flashing and peel the boomerang out.

The mold captured the details from the clay embellishments really well.

Liquid Plastic Casting

I mixed together Parts A and B of the Smooth-Cast Liquid Plastic and poured it into the mold and let it cure for 4 hours. I put baby powder on the mold before I added the resin to make sure it would come out more easily.

Refining Design

I made three more plastic casts of my boomerang and used different paints to decorate them and elevate them to more production-level pieces.

Sunset
Sunset

Red & Yellow

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Ocean
Ocean

Blue & White

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Sparkle
Sparkle

Rose Gold Glitter

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Shine
Shine

Gold

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