Unfolded Circle Remote 3 case silicone mold

Parts required:

• 10X 3mm screws 22mm lenght (or longer)
• 10X 3mm screws 10mm lenght
• 20X 3mm nuts
• Two part silicone (I've tested this with Silicone from Trollfactory with shore hardness 33a. But I guess a harder silicone would be better)
• Syringe with 4mm tip (for injecting silcone)

Printing instructions

• All parts can be printed without support. (The middle and top part have to be placed on the opposite side to print without support)
• The IR plug should be printed with a brim.
• The remote part has 3mm nuts embedded into the print. A pause has to be added at layer 7.2 to place the nuts.
• The parts can optionally be printed with transparent filament. This helps while molding to see if the whole part is filled with silicone.

Molding instructions

While molding time is essential. Two part silicone hardens after about 10 minutes. I've added instructions how to save time.

1. Put the top part and the remote part together with the 10 shorter 3mm screws.
2. Insert the 10 longer 3mm screws into the bottom part and place the middle part on top. (Check for correct orientation of the middle part by looking at the rounded corner at the bottom)
3. Mix about 100ml of two part silicone in a separate container. Optionally color pigments can be added. To save time the color pigments can be mixed with only one part of the two part silicone.
4. Pour about half of the mixed silicone into the bottom part of the mold to save time.
5. Quickly add the top part (with the remote part added to it) with the correct orientation and screw on the 10 3mm nuts. The nuts should be thightened fairly tightly to prevent silicone from oozing out through the gaps in the mold.
6. Insert the IR Plug at the top of the remote. Make sure it clicks into place inside the mold at the remote part to get a cleaner mold.
7. Place the mold upwards on the table
8. Fill the syringe with the remaining silicone and inject it into the elevated hole at the top of the mold.
9. Repeat the last step until the silicone pours out on the other side.
10. To remove trapped air inside the mold inject the remaining silicone with the syringe. After two or more injections you should see the air escaping the hole on the other side.
11. Secure the mold in place and wait two or more hours (or regarding the instructions of your silicone) for the silicone to harden.
12. Remove all the screws and carefully remove the top and bottom part.
13. The mold can be cleaned up with a sharp knife.

I've also added the Fusion 360 file if someone would like to make some adjustments. (e.g. to increase the size of the lip at the bottom so that the case could be cut into two parts after molding, so that the bottom part could be removed to plug the remote into the dock)