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Project Description
For this project, I designed a custom soap mold using Fusion 360 and then 3D printed it. The goal was to create a functional mold that could be used to cast soap efficiently while also showcasing my CAD modeling and 3D printing skills. The project required everyone to design a soap mold, but I wanted to go beyond just functionality. I incorporated personal elements into my design to show appreciation for someone special in my life—my best friend, Sam. He loves to bake, ski, and bike, so I integrated a loaf of bread, skis, and a bike into the mold design as a tribute to his passions and the presence he has in my life.
Brainstorming
When I began this project, I was inspired by the idea of making something unique and meaningful rather than just a standard soap mold. The goal was to create a mold that reflected my best friend’s interests while still being practical for soap-making. I wanted my design to serve as a daily reminder of the activities that bring him joy. To achieve this, I researched soap mold requirements (especially when CADding), looked into how to add intricate details to 3D prints, and explored different ways to incorporate personal design elements without making the mold too complex to use. I also created a sketch in Notability to visualize my design before moving into Fusion 360. Originally, my brainstorm was my format for my project but as i moved through the project, many things shifted around and I alotted room for a tagline!
Step 1: On our first day, we sketched a brainstorm of our design which we got approved by Ms. Tran
Procedure
Step 1: Initial Sketching and Planning:
Sketched different soap mold ideas in Notability.
Determined the ideal size for a standard soap bar.
Step 2: CAD Modeling in Fusion 360:
Created a new project in Fusion 360.
Sketched the base of the mold and extruded it to the required height.
Incorporated the loaf of bread, skis, and bike into the mold design.
Filleted edges for aesthetic pleasure and easy removal of the mold.
Step 3: Exporting the Model for 3D Printing:
Converted the Fusion 360 file to an STL format/file.
Imported the STL file into Bambu Studio for slicing.
Adjusted settings such as layer height, infill, and support structures.
Step 4: 3D Printing Process:
Used a Bambu Lab 3D printer.
Monitored print progress on the Bambu Handy App and made adjustments as needed.
Step 5: Evaluating the Printed Mold
Checked for any faults or gaps in my print, which at first looked complete but after pouring my soap, turned out to be a big fault in my project.
Once verified, used Ms. Tran's silicon plastique to shape my mold and let it dry
Unfortunately, I was not present on our soap-pouring day as I was traveling however, I left my mold in the Computer Lab and talked with Ms. Tran on how I should proceed and finished the project the following tuesday
Photo Documentation: Steps 2-7
Step 2: Master mold CADed in Fusion 360. NOTE, this was my final version before printing which Ms. Tran helped me revise
Step 4: Master mold made of silicone plastique. NOTE, patchwork was constructed due to limited supply of material.
Step 6: First finished product with a good imprint. NOTE, not a lot of the color came through, a good amount of the lettering and designs remained flat, and the soap shrunk in height due to leakage issues. A repour is being processed with Ms. Tran and the hope is to have resolved all of these issues.
Step 3: 3D Printing the mold and checking for any faults in my CAD
Step 5: Pouring the soap and adding fragrance and color to the project. NOTE, there was a lot of leakage due to faulty patching-this is being resolved with Ms. Tran
Step 7: Final finished master with little leakage. NOTE, there were issues with detail and popping it out as the patchwork didnt have enough time to dry.
Reflections
SOUL Reflections:
S - One of my strengths for this project was my loaf of bread. I tried to trace the image very carefully, so I'm pretty proud of it. I also like how the mountain range and skis turned out. In the beginning, i wanted to use images as references
O - In this project, I got the opportunity to explore Fusion 360 further, which definitely gave me more knowledge of the app. I learned to use several different tools by watching Ms. Tran work and by researching, so I think my Fusion 360 skills have definitely leveled up.
U - This project gave me an understanding of how working fast is important (especially with silicon plastique), but also how to pay attention to details and alter one part of a project without changing anything else. These skills definitely would have come in handy when I was CADding my project.
L - One of my limitations was that I accidentally made my mold by hulling my orginal design, which when i realized was a bad step, redid with Ms. Tran's help and support.
WISCR Reflections:
W -
I - The soap made in this mold was a gift for my best friend, Sam, so when CADding, I needed to think insightfully to come up with a design he'd like.
S -
C - I needed help from Ms. Tran a few times throughout this project, and I needed to be a clear communicator so that she could help me properly, which she did. I really appreciate her help throughout my process.
R -
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