I once made this lollipop for a special girl who likes chocolate and dinosaurs. She liked it a lot and we lived together happily ever after.
Step 1: Ideation Sketches
Sketching dinosaurs is fun! There are all kinds of dinosaurs. Big ones and small ones. And sometimes dinosaurs can be a bit mean... But of course the giant lollipop dinosaur had to be a cute one... With the sketches I experimented to get the proportions and detailing right, keeping in mind that the lollipop had to be molded (draft angle) and that it would look nice as a lollipop.
Step 2: CAD Model
I made the basic 3D geometry with t-splines for rhino, using the sketch as an under layer.
The t splines model was then imported into Z-brush for final detailing.
The STL model can be downloaded here.
Step 3: Making the Mould
With a CNC-milling machine the the dinosaur was milled from a piece of foam. Then with a thermo vacuum machine the mould was made from a 1 mm sheet of plastic.
Step 4: Pouring Chocolat
Using the method of au bain marie, about 1.8 kg of milk chocolate was molten. A PVC pipe with a diameter of 20mm was used as the stick.
When pouring chocolate into moulds it is important to temper the chocolate to get a nice shiny surface. If the chocolate is not tempered properly the surface will look matte and rubbish. See the instructions for temepering chocolate here: https://www.instructables.com/id/How-to-Temper-Chocolate/
Step 5: Give It to Someone Special
This is the lovely girl I gave the giant chocolate dinosaur. And we lived together happily ever after.