Creating Chocolate Molds

Wouldn't it be awesome to create a personalized chocolate bar shaped like your favorite video game controller, Lego brick, or even your cat's paw? Well, *this is your moment!*

We'll guide you through two simple stages:

1. Build the vacuum forming machine

2. Create your mold using vacuum forming

Than you can pour chocolate and enjoy your chocolate creation.

Pro tip: Once you've built the vacuum forming machine, step 2 is repeatable *ad infinitum*. Unlimited chocolate molds.

Supplies for Building the Vacuum Forming Machine

- 3 mm MDF board (450 x 350 mm)

- Glue (for assembly)

- EVA foam (for sealing and cushioning)

Supplies for Making the Molds

- A heat source (heat gun)

- A vacuum cleaner

- Metal clips (to secure the plastic sheet)

- Plastic sheets (PET, ABS, or polystyrene)

- A mold or object to be formed (3D-printed, laser-cut parts, or literally anything cool from your house rubber duckies welcome)

1. Download the provided PDF file with the design pieces.

2. Measure the diameter of your vacuum cleaner hose.

3. Adjust the size of the hole shown in the image above accordingly.

4. Use a laser cutter to cut the MDF pieces. Green lines indicate engraving; all other lines are cut.

1. Follow video for assembly guidance.

2. Glue the layers together to form a solid structure.

3. Make sure the top layer is perforated (for that sweet airflow).

4. Use EVA foam to improve suction and sealing. Cut 4 pieces of foam 115x7mm and glue them around the perforated layer. If you don’t have EVA foam at home, find something similar.

5. You will notice that one piece is not shown in the assembly video. We will not glue this piece; it is only used to clamp the plastic sheet when creating molds.

This is where creativity comes in!

- Think about what shape you want your chocolate to have.

- Use random objects from around the house (but maybe skip the car keys).

- Or design and 3D print/laser cut custom parts. If you will be printing the parts use PETG, because it’s more heat resistant.

Assembly steps:

1. Attach the vacuum forming machine to a working surface with a clamp

2. Connect the vacuum cleaner to the base.

3. Secure the plastic sheet in the clamping frame using metal clips.

4. Ensure the frame fits snugly over the vacuum platform.

Creating Chocolate Molds Using Vacuum Forming

5. Turn on the vacuum

6. Place your object on the perforated platform.

7. Heat the plastic sheet using a heat gun, and keep the heat source moving to avoid burning. Be careful not to overheat the plastic—some types can turn white and become brittle or crumbly when overheated.

That’s why it’s important to experiment with both the material and heating time. Don’t worry if it doesn’t work perfectly on your first try. Give it a few attempts and don’t give up! You can also try different types of plastic— plastic plates often work really well, but results may vary depending on the material.

8. When the plastic becomes soft and pliable, quickly place it over the mold.

9. Let it cool down before removing.

Ta-da! You just made your first custom mold. Go you!