Machining face shield molds - why 3D print when you can cast?

A quick project to machine up some aluminum face shield molds. While 3D printing can take 1-2 hrs per face shield headband, aluminum gang molds can create many headbands in parallel with fast cure times. Of course this is my channel, so plenty of things still went wrong despite being an easy project :)

📢 Twitter:   / breakingtaps  

I don't know where the pixels went at 9:59 😅

Mold files if you want to do similar or for inspiration: https://grabcad.com/library/3dverksta...
Original Face Shield model: https://3dprint.nih.gov/discover/3dpx...

First mold was cast aluminum tooling plate, second mold was 7075 (and much more pleasant to machine). I'm using Smooth Cast 60D, a semi-rigid urethane that cures in ~30minutes and takes ~24hrs to reach final cure. The urethane is actually a bit more floppy than I wanted, so I had to bulk up the headband model a little. 65D/66D is probably more appropriate.