Han Solo in Carbonite Chocolate Bar!




About: 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 checking out these sites: ebay.com, wikipedia, boingboing.net, makezine.com, in...

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!

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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

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    121 Discussions


    4 years ago on Introduction

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


    8 years ago on Introduction

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


    9 years ago on Introduction

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


    9 years ago on Step 2

    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.


    9 years ago on Step 3

    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!


    9 years ago on Introduction

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

    Nice to have an eatable 'ible!


    9 years ago on Introduction

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

    3 replies

    Reply 9 years ago on Introduction

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


    9 years ago on Introduction

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