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The challenge: Create a 3D printed case mold that incorporates a plaster section just for the finished surface.
Top right: The secret is M3 brass threaded inserts in pyramid-shaped 3D-printed mounts (I have just pressed them into the 4.4mm dia, 10mm deep, -3 degree tapered holes using a soldering iron). These brass/plaster pyramids embed into the plaster to provide a threaded hole that M3 bolts can screw into.
Upper left: We made a cross-section CAD drawing of a three-piece demonstration mold (upper left). The top plate has holes for the M3 bolts, air escape and natch clips and recesses for clamps to hold a 3D shell, with flanges, in place (not shown).
Lower left: The plaster pyramids have been screwed onto the upper plate.
Center left: The plaster was poured, and over-filled, then the top plate, with embeds, pressed down on top of it. After set, the plate was unscrewed and removed.
Bottom right: The plaster section has been reattached and natch inserts and embeds put in place. The plaster was not sanded or prepared, this is a demo.
What is this all about? A full master case mold, utilizing this technique, coming soon.
Buy me a coffee and we can talk