Abstract: The disclosed systems and methods include a mold assembly having a malleable mold (4), a moldable blank (2) and a bladder (1) positioned about the moldable blank (2) to transmit an external force applied to the mold assembly uniformly to the moldable blank (2) and hence to the malleable mold (4). The invention further includes a method of replicating a surface by use of the mold assembly. The method may include manipulating the malleable mold (4) to record the image to be replicated. This manipulation may include a physical engagement of the mold with a physical surface to be replicated. Alternatively, an image, e.g., photograph or laser scan of the surface may be transmitted to a computer numerically controlled (“CNC”) system. The CNC system then manipulates the malleable mold (4) to reflect the surface to be replicated. An activated moldable blank, e.g., a blank (2) fabricated from a thermo-forming material, is then positioned over the malleable mold.

Abstract: The disclosed systems and methods include a mold assembly having a malleable mold (4), a moldable blank (2) and a bladder (1) positioned about the moldable blank (2) to transmit an external force applied to the mold assembly uniformly to the moldable blank (2) and hence to the malleable mold (4). The invention further includes a method of replicating a surface by use of the mold assembly. The method may include manipulating the malleable mold (4) to record the image to be replicated. This manipulation may include a physical engagement of the mold with a physical surface to be replicated. Alternatively, an image, e.g., photograph or laser scan of the surface may be transmitted to a computer numerically controlled (“CNC”) system. The CNC system then manipulates the malleable mold (4) to reflect the surface to be replicated. An activated moldable blank, e.g., a blank (2) fabricated from a thermo-forming material, is then positioned over the malleable mold.