For our final project, our group set out to create a unique chess piece that combined creativity with technical skill. What began as a simple idea turned into a fascinating exploration of design, manufacturing techniques, and teamwork. Here’s how we brought Squidward’s House to life.
CHOOSING THE DESIGN
The first step was selecting a 3D shape for our chess piece. Initially, we considered two options, both visually appealing but overly complex for the casting method proposed for this project. Realizing these designs might not yield the sharp, clean lines required for the final product, we pivoted to a third option: Squidward’s House.
This shape struck the perfect balance between originality and simplicity, making it ideal for the combined methods of 3D printing, CNC machining, and silicone molding. The iconic, angular structure promised to translate well into the precision-oriented processes ahead.
PREPARING THE 3D FILE
Next, we processed the 3D model by splitting it into two halves and adding a mold base. The tasks were divided: Kyler and Alejandra used Meshmixer to cut the model in half, while Josefina focused on preparing the mold bases in SolidWorks.
This part required meticulous attention to detail. Josefina ensured the geometry of both halves aligned perfectly, including features like alignment holes and an air tunnel for the casting process. The goal was to create a seamless fit between the halves after the silicone and polyurethane steps. After Lyler and Alejandra used Vcarve to generate the tool path for the part.
The more intricate half of the mold was assigned to the 3D printer, while the simpler one was machined using the CNC. This distribution leveraged the strengths of both technologies and ensured efficiency in our workflow.
MAKING THE SILICONE-NEGATIVE MOLDS
Once the molds were ready, it was time to pour the silicone. This step required some careful math—silicone was one of the priciest materials in the project, so we needed an accurate estimate to avoid waste. After calculations, we determined that approximately 460 mL of silicone would be required (230 mL per half).
We prepared the mold frames, mixed the silicone thoroughly, and poured it slowly to minimize air bubbles. Watching the liquid settle into the negative space of our molds was immensely satisfying, as it marked the transition from design to reality. We then tapped them to remove bubbles and allowed it to cure overnight before removing the silicone.
CASTING WITH POLYURETHANE
The final step was casting the chess pieces using polyurethane resin. We decided to add a creative touch by varying the amount of black dye in each pour, creating a gradient effect across our final pieces.
Pouring the resin into the silicone molds felt like the culmination of all our hard work. We carefully de-molded the cured pieces, revealing beautifully detailed replicas of Squidward’s House. The color gradient added a unique flair, ensuring that each piece was distinct while maintaining the uniformity of the set.
REFLECTION
This project was more than just a technical challenge—it was a testament to collaboration and adaptability. From refining our design to navigating the intricacies of CNC machining and silicone molding, each step demanded precision and teamwork.
One of the most rewarding moments was seeing Squidward’s House come to life as a tangible object. It was a reminder of how far we’ve come in our understanding of prototyping and manufacturing, and it was a really nice closure ceremony for a semester of hard work.
Beyond the technical skills, the project reinforced the importance of planning, resource management, and communication. Squidward’s House now stands as a proud testament to what we can achieve as a team, and perhaps, as an unconventional yet stylish chess piece ready to defend its place on the board.
Cleaned works space
Cost Analysis
| Type | Cost | Price | Source | Quantity | Total |
| Materials | Silicone | $250/2 Gallons | Amazon | 460 mL | $10.13 |
| Wood | $8.08/8ft | Lowes | 3.5 in | $0.30 | |
| PLA | $19.99/kg | Bambu | 100g | $1.99 | |
| Polyurathane | $40.99/60oz | Amazon | 300g | $0.12 | |
| Hot Glue | $17.99/50 sticks | Amazon | 4 sticks | $1.44 | |
| Labor | Wood Working Operator | $21/hr | Ziprecruiter | 2 hrs | $42.00 |
| 3D Printer Operator | $26/hr | Ziprecruiter | 0.15 hr | $0.90 | |
| Mold Maker and Caster | $8.26/hr | CareerExplorer | 2 hrs | $16.52 | |
| Prototyping Engineer (You!) | $36/hr | Ziprecruiter | 7 hrs | $252 | |
| Overhead | Facility Cost (Machine Time) | $40/mont | Makers Barn | 4 hrs | $1.00 |
| Protoypting Total | $266.98 | ||||
| Production Total | $74.40 | ||||
The cost for prototyping the 5 pieces was $266.98, with most of the cost due to prototyping engineer labor, us. If the tasks were done instead by skilled laborers the cost is significantly reduced, by 72% to $74.40. Once the mold is produced the cost for each piece comes to $1.68. The price could potentially be further reduced by introducing an automated pouring and curing assembly line, which could also reduce production time.
