【Vacuum Forming】Simple 4 Steps: Double-sided Mold Making Has Tricks for 360-degree 3D Taiyaki!
Make your own 3D mold and cast a complete taiyaki! The most common and primary effect of vacuum forming technology is to place an object on a work platform, then lower a heated and softened vacuum forming sheet onto it. The sheet is shaped at high temperature and then cooled and set at the bottom of the platform. The finished molds usually have a "flat bottom cross-section"; today, let's do something different! With a 3D two-part mold, you can demold a complete small fish in 4 simple steps, creating the other half of the taiyaki's body. Here's how to do it:
3D two-part molds can be used to cast complex 3D finished products, not only breaking many design limitations but also allowing you to pour fillings such as food, plastic, clay, etc., into the mold to cool and set. Even hollow objects can be made! This reduces material usage, and because the material is injected into a closed two-part mold, it also keeps the work environment clean.
(Illustration of a 3D two-part mold /Image source: Pastryequipments)
．Design Model, Symmetrical Cross-Section
To vacuum form a 3D model using vacuum forming technology, the mold design needs to be different from usual. You must first decide "how to split the model into cross-sections." This is even more important if you are making an asymmetrical model! For taiyaki, we have two ways to create a cross-section: 
．Rounded Surfaces, Tight Fit
We have shared before that models with "rounded, curved surfaces" are more suitable for vacuum forming than "right-angled" shapes (Click here to see: 3 tips for DIY blister top covers with Mayku FormBox!). When vacuum forming, the high-temperature material sheet instantly contacts the rounded corners and follows the curve to completely cover the object. The finished product will then have a smooth, delicate surface.
Try to avoid sharp edges such as right angles, corners, or concave shapes on the blister object. You can add curved or slanted surfaces between the scales of the taiyaki. This will not only greatly increase the success rate of vacuum forming but also allow for easy demolding after the vacuum forming and cooling process!
．Design Vents to Expel Excess Air
By designing small holes on the model object, excess air between the blister material sheet and the model can be smoothly discharged through these vents during the instantaneous vacuum forming process. This effectively improves the forming fit, and the better the airflow, the finer the details of the vacuum forming! 
．Extended Fixing for Complete Sealing
Imagine that the top and bottom halves of the mold will be fixed together after pouring in chocolate. To ensure that the unset material is completely sealed within the mold, you can create a fixing area 6mm wide and 2mm deep at the bottom of the model using 3D modeling software. This will both completely seal the material and prevent chocolate from leaking during the setting process.
Although each object made is different, as long as you consider the above four steps when designing the model, and then use FDM 3D printing technology (e.g., Ultimaker, Prusa 3D printers, etc.) with high-temperature 3D printing filaments like PETG to create the object.
Finally, place the 3D printed mini taiyaki into the FormBox vacuum forming machine, along with transparent vacuum forming sheets. Once softened, press down on the sheet for instantaneous suction and shaping. Making a mold takes just 3-5 seconds – incredibly fast!
The FormBox vacuum forming sheets, certified for food safety, are not only safe for long-term human contact but also for food and dessert production.
Using the FormBox vacuum forming machine, you can quickly and infinitely duplicate ten molds from a single model within an hour. Tired of traditional molds? Now you can become your own mold manufacturer, reduce mass production costs, develop and create unique designs, and build your desktop dessert factory!
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