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This is an epoxy mold poured into an aluminum master mold frame. The gun impression was made from a wax jewelry pattern. The wax melted when the mold was heated to cure the epoxy, and it stained the cavity red. It also left some residue in there, so the first few injections were sort of pink. After that they were fine. It looks pretty good considering how fast it was made. The pattern barely fits into the mold frame, which actually worked out to be an advantage because only a short path was needed to create air vents extending from cavity to edge of epoxy.

The aluminum master mold is approximately 2 1/2"H x 5"W. The gun is a little more than 3" long and weighs 5.5 grams when made with low density polyethylene (LDPE).

This is a custom gasket made with a thermoplastic elastomer (TPE) resin, which is similar to rubber, except it can be remelted. The cavity was made by cutting a piece of laminated cardboard to the desired shape, then pouring the epoxy around it. The cured epoxy mold was clamped in the machine without using a master mold frame, which worked fine for this application.

 

This is an old toy airplane mold bought off the Internet. 

 

 

This is an old toy cowboy mold bought off the Internet.

 

 

This is an old toy soldier mold bought off the Internet.

 

 

 

 

 

 

 

 

 

 

 

 

The Glow-in-the-dark plastic pellets were melted down to make these pieces.

 

These are the cows (coming home).  Mooooooo........

 

 

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