Traditional
subtractive tool making and machining techniques were employed to
make a prototype.
This
included CNC machining of a “master” pattern, which
was
then used as the basis for creating a
vacuum-casted silicone mold. Molded parts were then carefully
hand-sanded and trimmed and finally painted
in our spray booth.
After
fitting, it was discovered that thr housing for the remote control
required an additional drilled hole.
However,
this hole was found to compromise the strength of the housing. On
our recommendation, the design
was
changed to allow for a slot instead of a hole, which in turn created
a better fit for the entire assembly.