Mold version 1.0
Technical documentation
07/13/2012
Solidworks files for the mold components. Designed to use 3/4" melamine board. Holes seen in boards are for holding bolts and inserts in the epoxy while it cures.
Other than the inner supports, the mold is meant to be held together by using a yet-to-be-designed external super-structure in order to extend the lifetime of the mold by avoiding repeated cycles of screwing the fragile melamine together. We are thinking about using 2x4s that the melamine is permanently fixed to that can be bolted and unbolted together.
Pouring will probably go best with the mold "upside down"; the walls poured first.
Additional holes may be made in order to assist with vacuuming out air bubbles. A dam may be added to fill in volume created by evacuated air.