Seamless 3D moulds

Enabling intricate, bespoke production for the luxury hospitality sector.

Background A five-star London hotel required a series of bespoke, high-quality chocolate designs tailored for specific seasonal themes and exclusive events. The project demanded a level of intricacy and structural delicacy—specifically thin-walled 3D designs—that standard commercial moulds could not reliably produce.

The Brief The objective was to develop a repeatable process for creating complex, one-piece 3D moulds with a fast turnaround. The requirements centered on maintaining high fidelity for delicate designs while ensuring the production process remained efficient enough to meet the rapid timelines of the luxury hospitality industry.

Technical Strategy (The Lab) The project began with a heavy emphasis on front-end design and client collaboration to ensure the technical drawings met the aesthetic requirements:

• Design Integration: We worked directly with the client to finalize product designs through high-fidelity renders, physical mock-ups, and detailed technical drawings.

• Specialised Tooling: To achieve the required "thin wall" geometry, we utilized a range of specialized digital and physical tools to simulate the flow and release of the medium before physical tooling began.

• Pricing Architecture: We developed a consolidated pricing model where the cost of bespoke tooling and setup was integrated into the initial production run, providing the client with clear, upfront cost-efficiency.

Mechanical Execution (The Workshop) To translate these intricate designs into physical products, we developed a proprietary moulding process:

• Seamless Silicone Tooling: We refined a technique for producing thin-walled, one-piece silicone moulds. This allowed for the clean release of delicate 3D shapes that would typically require multiple seams or complex assembly.

• Custom Support Enclosures: To maintain dimensional stability during the pouring and setting process, we designed and manufactured multi-part support enclosures tailored to each unique mould.

• Production Optimization: Based on the client's volume requirements, we calculated and manufactured the optimal number of moulds to ensure maximum throughput with minimum waste.

Validation and Result By collaborating with our sister company, RadChocs, we were able to set up and manage the full production cycle for the end products. This partnership allowed us to monitor the performance of the moulds under repeated use, ensuring they met the hotel’s rigorous quality standards.

The process has proven its worth as a scalable solution for luxury brands requiring bespoke, intricate hardware or confectionery tooling on shortened lead times.

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