Originally Posted by NuckinFutz
When I was looking into this a silicone mould made more sense to me, gotta be more comfortable! Are they a hollow shell, if so is this hard to do with silicone?
Oh, I thought you meant the negative mould material, which is this:
The shell i made from an epoxy called cold glaze. First I made a solid shell and hollowed it out with a dremel. Subsequent shells I cast hollow by using a "plug" made from a hot glue impression from the first shell. Like this:
Maybe the same method could be used for casting hollow silicone shell as well. The problem would be sealing the shells afterward, as virtually nothing sticks to silicone, except maybe other silicone. You could try casting the shell with the drivers inside, if using silicone. Even though my epoxy shells are a hard material, I find them quite comfortable. I was positively surprised.