Feb. 15-28
Below is the final design I created for the puzzle after simplifying it.
From these SketchUp designs I was able to make a stl file of the pieces and 3D print the following shapes:
Then I attempted to take the positive form (the 3D printed pieces) and use the thermoformer in the plastic lab to melt a sheet of plastic and then vacuum form it around the pieces to make the negative cavity.
The plastic didn't melt enough the first time and it wouldn't properly form the tight edges around the pieces. I needed a close fit so the poured chocolate pieces would nestle into each other correctly.

After melting a second piece I soon discovered that my idea about using this machine was not going to work.

The mold had the edges I was looking for, but the plastic was too rigid. In order to get the 3D positives out I had to cut and crack the plastic, making it unless. It also had many folds that would show up on the chocolate once it was poured and the mold wouldn't be flexible enough to get the chocolate out afterwards.
It was clear I needed a new method of mold-making and I sought help from the 3D print lab assistants.
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