FormArmor Pro is a Blender add-on for automated mold generation workflows, including shell creation, mold splitting, hardware placement, draft analysis, casting helpers, and batch STL export.

Version: 5.0.0

Compatibility:
- Blender 4.2.0 and newer for extension packaging
- Legacy add-on install remains supported through bl_info in __init__.py

Installation:
1. Open Blender.
2. Go to Get Extensions.
3. Choose Install from Disk.
4. Select the packaged ZIP file.
5. Enable FormArmor Pro.

License:
GPL-3.0-or-later
_________________

FormArmor Pro Documentation

Overview

FormArmor Pro is a Blender add-on for automated mold generation workflows. It includes tools for shell creation, mold splitting, hardware placement, draft analysis, casting helpers, silicone volume estimation, and batch STL export.

The add-on is designed to help prepare mold parts directly inside Blender for workflows such as silicone casting, 3D printed mold forms, prop making, sculpture, product prototyping, and small-scale production.

Version

5.0.0

Compatibility

• Blender 4.2.0 or newer
• Extension packaging support through blender_manifest.toml
• Legacy add-on information is also included through bl_info in __init__.py

Installation

1. Open Blender.
2. Go to Get Extensions.
3. Choose Install from Disk.
4. Select the packaged ZIP file.
5. Enable FormArmor Pro.
6. Open the 3D Viewport.
7. Press N to open the side panel.
8. Go to the FormArmor tab.

The add-on is located at:

View3D → N-Panel → FormArmor

Main Workflow

1. Prepare Your Model

Before using FormArmor Pro, select the mesh object you want to create a mold from.

For best results:

• Apply scale and rotation.
• Use clean mesh geometry when possible.
• Remove unnecessary loose geometry.
• Check that the object has a reasonable real-world scale.
• Save your Blender file before running mold generation tools.

Complex, non-manifold, or very high-poly meshes may require cleanup before mold generation.

2. Setup & Control

Use the setup tools before building the mold.

Available tools include:

• Run Preflight Check
• Mesh optimization options
• Scan cleanup options
• Cleanup resolution controls

The preflight check helps identify potential problems before generating the mold.

3. Outer Shell & Dimensions

This section controls the generated mold shell.

Available settings include:

• Outer shell type
• Clearance
• Wall thickness
• Open base option
• Bottom trim
• Boolean solver settings

Clearance controls the space between the original object and the mold shell.

Wall Thickness controls the thickness of the generated mold body.

Adjust these values depending on the size of your model, the intended material, and the strength needed for the final mold.

4. Mold Split

FormArmor Pro supports different mold split workflows.

Available options include:

• No split
• Automatic split
• Manual split using cut planes

For automatic splitting, you can define the number of parts on the X, Y, and Z axes.

For manual splitting:

1. Click Add Cut Plane.
2. Position the cut plane where you want the mold to separate.
3. Build the mold.

Additional post-editing tools include:

• Split Selected Part
• Merge Selected Parts

These tools can be used to refine mold parts after the initial generation.

5. Build Mold

After setting up the shell and split options, click:

BUILD MOLD

The add-on will generate the mold geometry based on the selected object and the chosen settings.

Processing time depends on model complexity, mesh density, and boolean settings.

6. Hardware: Tabs & Keys

This section helps create alignment and assembly features for the mold.

Available features include:

• Registration keys
• Screw tabs
• Automatic hardware placement
• Manual placement using the 3D cursor

Adjustable settings include:

• Key size
• Key tolerance
• Hole diameter
• Tab size
• Tab depth
• Tab thickness
• Automatic tab count
• Automatic key count

Recommended workflow:

1. Select the mold parts.
2. Use Close Mold Parts.
3. Use Auto-Place Hardware.
4. Manually add keys or screw tabs if needed.

Registration keys help mold parts align correctly. Screw tabs can help with assembly and clamping.

7. Draft Angle Analysis

The draft analysis tool helps identify areas that may be difficult to release from the mold.

Available settings include:

• Pull axis
• Draft angle limit
• Intelligent analysis
• Silicone flexibility bonus

Click:

Draft Angle Analysis

The analysis uses a color guide:

• Red: undercut or high-risk area
• Yellow: borderline area
• Green: safer draft angle

Use Clear Draft Analysis to remove the analysis display.

Draft analysis is intended as a visual guide. Always review the model manually before real-world production.

8. Casting: Pouring Basin & Vents

This section adds basic casting helper geometry.

Available tools include:

• Pouring basin
• Smart vents
• Silicone volume calculation

Adjustable pouring basin settings include:

• Top radius
• Bottom radius
• Depth
• Embed amount

Adjustable vent settings include:

• Vent count
• Vent diameter
• Vent depth
• Vent embed
• Vent margin

Click:

Add Pouring Basin & Vents

to add the casting helper geometry.

Click:

Calculate Silicone Volume

to estimate the silicone volume.

The silicone volume estimate is only an approximation. Always allow extra material when preparing real casting work.

9. Finalize & Export

This section is used to prepare and export the generated mold parts.

Available tools include:

• Export directory selection
• Batch STL export
• Finalize mold

Choose an export folder, then click:

Batch Export STL

to export the generated mold parts as STL files.

Use:

Finalize Mold

only when you are ready to permanently apply and lock the boolean operations.

Finalizing is destructive. Save a backup of your Blender file before using this command.

Important Notes

FormArmor Pro relies on Blender’s native geometry and boolean systems. Because of this, results can vary depending on the input model.

The developer cannot guarantee that every 3D model will generate a perfect mold without artifacts, errors, or crashes. Complex, non-manifold, or excessively high-poly meshes may cause unexpected behavior.

Users should always verify:

• Scale
• Draft angles
• Wall thickness
• Hardware placement
• Split lines
• Venting
• Estimated silicone volume
• Exported STL files

before 3D printing, casting, or using physical materials.

Troubleshooting

The add-on does not appear

Make sure FormArmor Pro is enabled in Blender. Open the 3D Viewport, press N, and look for the FormArmor tab.

The mold does not build correctly

Try the following:

• Apply scale and rotation.
• Clean the mesh.
• Reduce mesh density.
• Increase clearance.
• Increase wall thickness.
• Try another boolean solver.
• Run the preflight check before building.

Boolean operations fail

Boolean operations may fail on complex, messy, non-manifold, or extremely dense meshes. Clean or simplify the model and try again.

Hardware placement does not work as expected

Check that the correct mold parts are selected. You can also place registration keys and screw tabs manually using the 3D cursor.

Export does not work

Make sure an export directory is selected and that Blender has permission to write files to that location.

License

FormArmor Pro is licensed under:

GPL-3.0-or-later

The full license text is included in the package.

Disclaimer

This software is provided as is, without warranty of any kind.

The user is responsible for verifying the generated mold design before physical manufacturing. This includes checking scale, printability, draft angles, hardware placement, material volume, and suitability for the intended casting process.