Dual cast slush mold system, methods, and apparatuses

A method of producing a part, the method comprising:

• heating a mold having a negative side and a positive side, wherein heating the mold is performed while the mold is held stationary;
• rotating the mold in a range of 30 rpm to 60 rpm for a duration in a range of 10 seconds to 45 seconds to cause at least a portion of a first polymeric powder to contact the negative side of the mold;
• molding a first layer on the negative side of the mold by melting at least a portion of the first polymeric powder;
• rotating the mold in a range of 30 rpm to 60 rpm for a duration in a range of 10 seconds to 45 seconds to cause at least a portion of a second polymeric powder to contact the first layer;
• molding a second layer on the first layer by melting at least a portion of the second polymeric powder;
• and
• cooling the mold by spraying the positive side of the mold with a cooling fluid to reduce the temperature of the first layer and the second layer, wherein cooling the mold is performed while the mold is held stationary.

A method of producing a part using a dual cast slush mold system, the method comprising:

• providing a mold having a negative side and a positive side;
• heating the positive side of the mold using a first heater, the first heater comprising one or more infrared emitters;
• heating the negative side of the mold using a second heater, the second heater separate from the first heater, the second heater being a convection heater;
• connecting the mold to a first box containing a first polymeric powder;
• rotating the mold and the first box, in a first rotation step, during which at least a portion of the first polymeric powder melts and forms a first layer on the negative side of the mold;
• disconnecting the mold from the first box;
• connecting the mold to a second box containing a second polymeric powder;
• rotating the mold and the second box, in a second rotation step, during which at least a portion of the second polymeric powder melts and forms a second layer on the first layer;
• disconnecting the mold from the second box;
• heating the second layer using only the second heater, during which the second layer expands in thickness;
• compressing the second layer;
• and
• cooling the mold to reduce the temperature of the first layer and the second layer.