【Vacuum Forming】4 Simple Steps: The Trick to Two-Part Molding for a 360-Degree Taiyaki!
Create 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, press down on a heated and softened vacuum forming sheet, thermoform it at high temperatures, and then cool and set it at the base of the platform. Typically, the finished molds have a "flat-bottomed cross-section." Today, let's try something different! For 3D two-part molds, follow these 4 simple steps to demold a complete small fish, growing the other half of the taiyaki's body. Here's how:
3D two-part molds can be used to cast complex 3D finished products, breaking many design limitations. Simply inject fillings such as food ingredients, plastics, or clay into the mold, and once cooled and solidified, the item is complete. Even hollow objects can be made, reducing material usage. Moreover, since the material is injected into two closed mold halves, the working environment remains clean.
(Illustration of a 3D two-part mold / Image source: Pastryequipments)
．Design Model, Symmetrical Cross-Section
To vacuum form a 3D model, the mold design is different from usual; you must first decide "how to split the model into cross-sections." This is even more crucial for non-symmetrical models! For taiyaki, we have two ways to create a cross-section: 
．Rounded Corners and Curves for Tight Fit
We have shared previously that models with "rounded and curved surfaces" are more suitable for vacuum forming than "right-angled" shapes (Click here to see: 3 tips for DIY blister packaging to advance quality!). During the vacuum forming process, when the high-temperature material sheet is pressed down and instantly contacts the rounded corners, it will smoothly conform to the curve and completely wrap around the object. The finished product will then successfully have a smooth and delicate finish.
When vacuum forming objects, try to avoid sharp edges like right angles, corners, and concave shapes. You can add curves and slopes between the taiyaki scales. This will significantly increase the success rate of vacuuming, and after forming and cooling, demolding will be smooth and easy!
．Design Vent Holes to Expel Excess Air
Design small holes on the model object. During the instant vacuuming process, excess air between the vacuum forming material sheet and the model can be smoothly expelled through the vent holes, effectively improving the molding fit. The better the airflow, the more refined the details of the vacuum formed product! 
．Flared Fixation for Complete Sealing
Imagine that the top and bottom mold halves will be fixed together after injecting chocolate. To ensure the still-liquid filling material is completely sealed within the mold, you can expand a 6mm wide, 2mm deep fixing area at the bottom of the model in 3D modeling software. This will both completely seal the injected material and prevent chocolate from leaking during the solidification process.
Even though each object you make is different, as long as you consider the four steps above when designing your model, and then use FDM 3D printing technology (such as Ultimaker, Prusa 3D printers, etc.) with high-temperature 3D printing filaments like PETG to create your object.
Finally, place the 3D printed mini taiyaki into the FormBox vacuum forming machine. With the transparent vacuum forming material sheet, soften it and then press it down to instantly vacuum form the mold. Making one mold takes only 3-5 seconds – incredibly fast!
The FormBox vacuum forming material sheets, certified safe for food contact, can not only be in prolonged contact with humans but also be safely used in food and dessert production.
Using the FormBox vacuum forming machine, you can quickly replicate ten molds from a single model within an hour. Tired of traditional molds? Now you can become your own mold manufacturer, reducing mass production costs, developing and creating your own unique designs, and building your tabletop dessert factory!
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