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How to Design and Make Custom Chocolate Molds with Desktop Vacuum Forming

The FormBox allows you to easily replicate objects in a wide variety of materials, including chocolate. This means you can create custom chocolate molds with food stuffs and everyday objects in minutes. To demonstrate just one example of how to use desktop vacuum forming for chocolate molds, we created bespoke molds from seashells and filled them with tempered dark chocolate and salted caramel.

How to Make Custom Chocolate Molds with Vacuum Forming

Some fun objects for chocolate mold-making - what will you try on the FormBox

How to Make Custom Chocolate Seashells with a Thermoformed Mold

To have a go at this Mayku make, you'll need to gather a few supplies before you get FormBox-ing...


  • Assorted shells - to create your molds from
  • Dark chocolate
  • Dark muscovado sugar
  • Double cream
  • Caster sugar
  • Sea salt

How to Choose the Right Object for Vacuum Formed Mold Making

Before you power ahead with the fun forming action of creating custom molds with the FormBox, there are a few design principles that are smart to understand to ensure you have the best experience. For further detail on designing for vacuum forming check out our blog guide by Agustin Arroyo. In brief, here's a few tips to help you out:

  • Forms which work best in the FormBox have draft angled sides and are wider than they are tall and have no undercuts.
  • For objects that are spherical (or similar), the most straightforward technique is to cut them in half and create two molds which can subsequently be joined together. Also known as a two-part mold.
  • Alternatively, a bed or skirt can be created for the object to sit in – clay is a quick and easy material with which to add this support and fill in any undercuts.
  • Any recesses should be drilled into so as to allow air to flow through to the base of the template and improve the forming of the mold. This helps improve the quality of your mold but isn't always necessary.
  • To create a smooth surface surrounding the mold, a piece of 20cm x 20cm MDF of up to 3mm can be inserted onto the FormBox bed.

Shells for Making Thermoformed Chocolate Molds

The lucky shells - ready to be vacuum formed with the Mayku FormBox

How to Make a Custom Chocolate Mold using a Vacuum Forming Machine

Once you've found your original object, creating that perfect custom mold couldn't be easier. You can make one mold in minutes and be ready to cast into it instantly. Here's the steps to follow for a successful vacuum formed mold.

  1. Arrange objects in the FormBox, making sure they are evenly spaced and not too close together and not too close to the edges.
  2. Insert your chosen thermoplastic Mayku Sheet, watching as it heats up and droops in the centre, this is the sign that it's ready to go.
  3. Gently release the handles and allow the plastic to form around the template pieces. Leave for a few seconds to cool and then remove from the machine.
  4. Your mold is ready to use – make sure you wash it before putting any edible ingredients inside.


  1. Temper the dark chocolate and brush evenly into the mold, covering the edges. Scrape away any excess and allow to cool.


  1. Heat cream and muscovado sugar over a bain marie.
  2. Heat the caster sugar separately in a heavy based pan until it’s golden then remove from heat.
  3. Add the cream mixture carefully to the sugar mixture, stirring well once the bubbling has subsided. Add salt and leave it to cool.


  1. Pour the caramel mixture into the chocolate shells in the molds. Chill.
  2. Carefully spoon over tempered dark chocolate to seal, and chill once again.
  3. Remove from the molds using your thumbs to apply pressure to the thickest part of the chocolate.

Custom Chocolate Seashells with a Mold Made on the Mayku FormBox Vacuum Former

The finished chocolate shells made on the Mayku FormBox

Want to learn more? Head to @TeamMayku on social media for more delectable mold making inspiration, explore our resources for Chefs and Chocolatiers or request to Speak to a Specialist today to find out how the FormBox could improve productivity and creativity in your kitchen.

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