The chocolate master pattern was created in Fusion360, then vacuum formed on campus (FADA Lab) to produce a plastic mould in which the chocolate could be casted 3 times. My first design was too small and thin, although the measurements were right; nevertheless, a second effort at a 2 hour print produced a finer, larger solution to the mould.

With the vacuum forming, it was attempted 3 times until a final, smooth finished was conducted and in great conditions for a non-faulted chocolate to be produced.

Sheet metal was locally sourced in Nelspruit (Mbombela), out of the AMI steel work workshop (some off scraps from airplanes and helicopters). The 5m x 7m steel was cut to measurements of 250mm x 90mm. To protect the sheet, the metal rounding was bent over another piece of steel to the perfect rounding. I was able to use this workspace to bend my sheet to the desired design.

The initial idea was to keep to the plain metal sheet, but to personalized it, I added a piece of 16 mm thick Matumi wood that was engraved with the St. Regis logo and name while the sheet metal had the names of "chocolate" and "soap" as a placement area incase someone is unsure of what product it is.

Using Pratley Steel Quickset glue, I roughened the bottom (with sandpaper) of the sheet metal and also the wood after measuring where it would be placed. After combining the two tubes of glue and placing them on the wood, I clamped both sides with a piece of wood to protect the sheet metal from any scratches during the 24hr set time.  

As seen above, a 16mm thick MDF with the dimensions of 50mm by 80mm. With a Dremel 3000 and a 5 mm engraving bit, I hand engraved the coral and the ocean/wave type in the middle and top of the MDF. Sanded it down to a smooth finish and covered it with fine body filler for the silicone to expand around the MDF, instead of it making small dents in the finished mould. The black seen is acrylic paint, used to cover up the fine work where the fine filler couldn't get to.