Introduction: Han Solo in Carbonite Chocolate Bar!

This is an instructable on how to make your own Han Solo in Carbonite chocolate bar! But using these basic instructions you can make ANY kind of chocolate bar or mold!

So what I used was food grade silicone. There are many brands who have different names for it.

There are different grades, cures, durometers, (how flexible it is)pot life, (how long you have to work with before it cures)

So you must double check each products specifications.

The main difference is that food grade silicone is non toxic and is platinum cured versus tin cured.

The specific product I used was Smooth on Sil 940, sampler size.

It's 2 lbs and about 40 bucks. But it's easily enough to do a few molds. The kit comes with complete instructions and there is a phone tech support in case you get lost.

Just googling "food grade silicone" will find you what your looking for.

Here is the same product, different company, on ebay:

Find some place near you that sells it, Tap plastics will be carrying it soon.

You will need the following materials:
-Han Solo in Carbonite toy
-Foamcore (it's usually white paper with a foam core)
-Glue gun with a few sticks
(Big tip here, you can use Legos instead of the foamcore/gluegun method, I'll explain later)
-Food grade silicone ( if you ever wish to use food products in the mold, otherwise regular silicone will work)
-Baking chocolate

I watched all of the videos available on Tap plastics website before I even started. I suggest you do the same to make the process full proof :) Especially on mold making!

Remember you can cast any object. And if you can cast any object you can mold anything into chocolate!

Someone out there is already working on a battle of hoth scene in chocolate. Complete with chocolate AT-ATs and powdered sugar for snow!

Step 1: Building Your Box Mold.

You have to build a box around your object out of foamcore.

Or even cooler you can use your old Legos to make a box mold.
Here is a link with the basics.

I however had my Legos maliciously taken away from me at a very early age so I'll be using foamcore.

First using your glue-gun, glue your object to be molded onto a flat foam core peice. You want to create a seal all around the base of the object so silicone does not flow under the object.

Using the glue gun then glue a box around the object leaving a quarter of an inch to a half inch all the way around. This will make the mold strong and less prone to warping.

The particular food grade silicone, the Smooth sil 940 is easy to mix. I just poured the complete bottle into the silicone tub.
However each silicone is different. Double check your silicones instructions.

'Pouring silicone'
You're going to pour in your silicone. Best way is to start at a corner and let the silicone flow in/onto the mold and not pour directly on the mold. This helps reduce bubbles.

Let it cure for 24 hours then you remove the cured silicone from the foamcore box mold.

It's going to need post curing in a oven but use the instructions for your specific silicone product.

Step 2: Melting the Chocolate, Making Your Mold

The silicone will take 24 hours to dry.

The specific product I used needs post curing in the oven for 4 hours at 212 F.

After baking your mold, wash it out and it's ready to use.

There are two ways to melt chocolate
Here are the videos I followed, using only the first two links.

Basically you put a pot in boiling water and your chocolate into that pot. If you put your chocolate on a regular pan over a flame you risk burning the chocolate!

Melted chocolate on fingers isn't as bad as a melted glue stick on fingers! And you get to lick them clean.

mmmm chocolate...

Step 3: Demolding

After a few hours in the fridge Han Solo was ready for Jabba, I mean for demolding. Here is the final product. Since I gave it to my brother early I now plan on making a wrapper with graphics for my brothers birthday present. Mom's life mask was given as is and she loved it.

I noticed a few air "voids" on Han Solo and these are just really small spaces that are hard for the chocolate to flow too. In order to avoid the voids just use the spatula to force the chocolate into the small spots. Also a vibrating source will let the bubbles flow out. Sometimes massaging tools are just enough.

The possibilities of chocolate making are unlimited. Some other ideas include making a hollow cast, much like chocolate bunny and then pouring ice cream into the hollow cavity. Or adding cocoa powder, or powdered sugar, there are special edible transfer sheets that are often seen on the more expensive Godiva chocolate.

This was my first attempt and I hope you enjoyed it and it inspires you! Feel free to email me or instant message me!

All comments are welcome!

Chris Koehne


aliphatic made it! (author)2015-06-20

I put a chewy caramel center in mine for a more authentic trapped-in-carbonite mouth-feel.

avarshney made it! (author)2011-03-11

it mummy in chocolate .. fun to eat it .. hope the taste will be good ...... haha
polycarbonate sheets

thepelton made it! (author)2011-03-01

I wonder what Harrison Ford would think of this?

conrad2468 made it! (author)2009-12-19

Im going to "makerbot" one and then cast it in silicone.

M4industries made it! (author)M4industries2009-12-20

 DUDE! Those things are amazing!

I want one of those kits so badly!

porcupinemamma made it! (author)porcupinemamma2010-02-14


thepelton made it! (author)thepelton2011-03-01

Same here. I want a makerbot myself.

conrad2468 made it! (author)conrad24682009-12-20

U work for adam and jamie?!?! And they r awesome things! tricky to run though :(

M4industries made it! (author)M4industries2009-12-20

 First Question: No, I don't. If I did, it would be M5 Industries instead of M4.
Second Part: I've seen one at Techshop, but have lived in envy of those who have them. 

conrad2468 made it! (author)conrad24682009-12-20

lol my memory is failing :s i was gonna say that id print u out one for a mythbusters autograph ha ha ha....

M4industries made it! (author)M4industries2009-12-21

 No worries man. You're the third person whose said that since I joined Instructables!

Morriscow made it! (author)2010-06-16

its kinda creepy you want to eat your mom

Big_Mike_ made it! (author)Big_Mike_2010-12-20

I thought so too

lane29 made it! (author)2010-12-20

has anyone thought about making a cake like this or a cookie orsucker???

TrueDave made it! (author)2010-11-20

Any idea on a flexible white resin you could use in that mold? Name ? Company?

imshanedulong made it! (author)2009-07-09

Where did you get the Hansolo model?

Sultaana made it! (author)Sultaana2010-10-21

You can find Han Solo carbonite toys on ebay "loose" for under $5.

LobosSolos made it! (author)2010-10-19

You can also microwave the chocolate to melt it. If you do this, do it on a lower power setting and don't do it for more than two minutes at a time. Stir it in between sessions and the more liquid it gets the shorter time periods you should use. Also if the humidity isn't too high then you can use chocolate chips, but if the humidity is higher than chocolate chips will not melt properly. Which kind of baker's chocolate did you use; milk, semi-sweet or unsweet? The type determines the sweetness of the final product.

Boba Fett Costumes made it! (author)2010-09-25


ac604606 made it! (author)2010-09-12

Hey Chris,
The chocolate looks great. If you are really interested in continuing your work with chocolate bars you should learn how to temper chocolate! It helps your chocolate keep its "snap" after it has cooled, and it also allows it to set at room temp in 5 minutes as opposed to a few hours in the fridge. If you want some tips just let me know!

kevinhannan made it! (author)2010-09-11

So doing a Jabba the Hut version would be just plain greedy, huh? ;-)

Nice to have an eatable 'ible!

MdP1632 made it! (author)2010-08-31

Great job. I think what you have done here is amazing. But is kind of creepy to eat your mom.

jaythedogg made it! (author)jaythedogg2010-09-11


red-king made it! (author)red-king2010-09-09

nah... just sprinkle a bit of salt and pepper on 'em. ...Oh, wait. we're talking about chocolate bars.

Ghost Wolf made it! (author)Ghost Wolf2010-09-09

But who cares about who eats who all what matters is that they are tasty!

Ward_Nox made it! (author)2010-09-10

if youbuy the r2d2 ice bucket it comes with a ice cube mold of Han in carbonite just FYI

Senior Waffleman made it! (author)2010-09-09


prodo123 made it! (author)2010-09-09

Person 1: I ATE YOUR MOM :O lol
Person 2: HOW DARE YOU n00b
Person 1: (Holding mom chocolate face bar)

zascecs made it! (author)zascecs2010-09-09


seabananers made it! (author)2010-07-29

i'm working on a stopmotion action figure film for my cousins birthday present (he loves ROTJ) so im gonna use this with the action figuer inside and melt the chocolate when leia/boush saves him

rawknexstuff made it! (author)2010-01-09

You could use this method to make Lego shaped ones you could actually build with!

D10D3 made it! (author)2009-12-14

This is brilliant. I am SO making carbonite bars!

rorsie made it! (author)2007-09-10

nice one, guess what i'm going to mould..............

andross52 made it! (author)andross522009-11-24

 Do tell.

tino7777777 made it! (author)tino77777772009-11-24

her collage degree. :)

sciencensorcery made it! (author)2009-07-30

Hi! I just wanted to let you know I featured this in my weekly column on Fandomania:

Fandomestic: 5 Star Wars Sweets

Fredz1974 made it! (author)2007-05-12

This was awesome! Great job. Seriously though, how did you make the face mask, and how long did it take. I would try this with baby foot prints! Way to go!!

wendybird made it! (author)wendybird2008-03-17

you definitely need to be careful with babies.. skin needs to breath, and the cautionary tale around the sculpture lab was that someone tried to make a cast of his new baby and the baby died even though his/her airways were not blocked at all!! just the feet might be fine, but i'd hate to see someone go here and say "hey- a chocolate baby!!"

cherylmmorris made it! (author)cherylmmorris2009-07-16

Use a baby doll, not a real baby! Or you could maybe use a plaster mold for making an imprint of your real baby's foot, then cover it with tin foil carefully trying not to wrinkle it & use that to mold the chocolate.

FreakCitySF made it! (author)FreakCitySF2007-05-12

Baby feet! great idea! And casting them would be a cinch because they are a simple box mold like for the carbonite! The face took bit a longer as I had to build a custom box around the face. I had limited supplies of silicone and If i had made a simple box mold I would have used way too much material. So instead I custom formed and cut foam core peices around the face so the silicone was only half an inch thick uniformly all around. Just enough to hold the shape. I may have a few pictures of that if you want to see what I'm talking about. email me for them. It's just as simple though.

drcrash made it! (author)drcrash2007-07-14

Another way to do it is to (1) roll out a sheet of modeling clay using something round supported on a couple of strips of something the right height near each end, with the clay in between the strips. (2) cut pieces of the modeling clay and put them on to make a uniform-thickness layer (3) pour a plaster support mold over that, then take it off and remove the clay (4) put the plaster mold back in position around the original model, and pour the silicone in between.

bowakowa made it! (author)bowakowa2007-05-21

I recommend insta-mold, which can be had at most art supply stores for the first negative. Then pour hot wax in for a positive. Then follow intructable above.

Fredz1974 made it! (author)Fredz19742007-05-21

Thanks Bowakowa! I will try that!

drcrash made it! (author)drcrash2007-07-14

Insta-Mold is actually "alginate." There's lots of sources of alginate, and it's great stuff for making temporary molds to cast one or two or three copies of something. (And much cheaper than silicone.) Places that sell "life casting" (a.k.a. "lifecasting") materials have alginate. I use the slow-setting alginate from Pink House. Insta-mold sets too quickly for my taste.

Rossiroller made it! (author)2008-12-17

Wow you could make chocolate legos and build stuff then eat it!

Kuhan made it! (author)Kuhan2009-04-16


thepelton made it! (author)thepelton2009-04-11

I recall seeing building block shaped opaque colored candy, I think it was something like SweetTarts.

fwjs28 made it! (author)fwjs282009-04-11

that was fun stuff man!

Nameless37 made it! (author)Nameless372009-02-01

awesome idea

skaldedgrifon made it! (author)2009-01-26

Neat, thanks for sharing.

About This Instructable




Bio: I'm an industrial arts major at SFSU with an empahsis in product design. I'm online all the time and I find myself constantly ... More »
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