Toys such as this are typically made through injection molding.
Often castings of an object are made by injecting material into a mold. The mold may be made up of two or more pieces, which are closed before injection begins. The main benefits of this process are reduced seam lines in the product as well as allowing you to use only as much casting material as you need with little waste. When injecting material into a closed silicone mold, it is essential to take several steps to insure that the casting comes out right. If your mold was designed for this purpose with the holes already in place, begin at Step 6.
Instructions
1. Determine the best injection point in your mold. Ideally, this should be a place that is not easily seen on the cast, such as the back or bottom. Mark the point with a marker.
2. Determine the highest points in the cast. Mark these with the marker.
3. Drill a hole in the silicone at the injection point. The drill bit should be the same diameter as the tip of the syringe. Use an extremely sharp drill bit to prevent the rubber from grabbing onto the bit. It's a good idea to have a friend hold the mold in place just in case the bit grabs the silicone; otherwise the entire mold will spin and could cause injuries.
4. Drill small holes in the highest points. Use the smallest bit you have for these as they are simply to allow air to escape as you inject the casting material.
5. Mark the holes in the mold shell and drill it out as well.
6. Apply a thin coat of silicone mold release or hand soap to the entire inner mold surface with a paintbrush. Allow it to dry and buff out the excess with a paper towel.
7. Close the mold and strap or clamp it shut tightly.
8. Mix the casting material according to its instructions.
9. Pour the casting material into the syringe.
10. Insert the tip of the syringe into the injection hole and inject the casting material.
11. Allow the casting material to run out of the air release holes for a few seconds before plugging each one with a bit of clay. This allows any air bubbles in the casting material to escape the mold.
12. Once the mold is filled, remove the syringe and plug the injection hole with clay.
13. Allow the casting material to cure and dry.
14. Remove the cast from the mold.
15. Remove the knobs left by the holes with a razor blade and sandpaper if needed.
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