This how I made the Twister I and Twister II
I designed the puzzles at the same time in Solidworks. I made them as simply a shell to go around a Cube4you White DIY cube. (I still don't know the difference between "Type a" and "Type b" etc. If anyone can explain that or point me towards a thread that does, that would be greatly appreciated!)
I printed them on the CU Boulder Engineering School's FDM machine. They turned out better quality than usual. I then began making the molds. As usual, I used Oomoo 25. That stuff is amazing! My desk is always covered in tools and random stuff by the end of the process, but I'm getting better at avoiding spills.
This was my first time trying to use Smooth-Cast 300. At some point, Drewseph said that Alumilite is crap, and the best stuff to use is Smooth-Cast 300, Thank you Drewseph, you were dead right! I am never going back to Alumilite.
(From now on, I unfortunately don't have any pictures of the building of Twister I. All I have are pics of Twister II. Oh well.)
I got impatient to see what the cubes would look like, that instead of waiting for the C4Y cubes to arrive, I just hot-glued the cast pieces onto my good black cube. Here it is in progress:
Once the C4Y cubes arrived, I tuned them to my satisfaction, then began gluing the pieces on. Here is an edge piece from Twister II:
Then, I filled the appropriate pieces with Smooth-Cast, and then I used my dremel to grind the piece down to the correct swept shape.
I did a few rounds of filling and sanding to hide the seams and to smooth out the surfaces. Then I taped up the inner surfaces, and spray-painted the outer surfaces.
Finally, I stickered both Twisters. Here they are finished:viewtopic.php?f=15&t=13758