This is a mold to cast replacement skins that will fit the Simulab Trauma Man. Currently used by the Indiana University Simulation Center at Fairbanks Hall.

3D print the parts in PLA with a standard preset (No special 3D printer is needed, every part will fit on a 220mm x220mm printer bed). Since this is a detailed functional part, I'd recommend 0.2mm layer height with at least 4 perimeter walls and at least 10-15% infill, though much more than that is probably overkill.

Following printing, seal with an acrylic spray. If you intend to cast standard platinum cure silicone in this mold it is VERY important that you use an acrylic seal and not polyurethane or some other spray seal as it may inhibit the hardening of your silicone. I used Krylon Crystal Acrylic Spray Coating. If you like, you can sand afterwards to improve the smoothness, but it isn't really necessary.

You should use a clear silicone dyed to flesh tone with an appropriate silicone pigment in order to match the skin tone of the TraumaMan mannikin. I used a cheap 15A silicone ( NicPro, from Amazon, ~$80/140oz) and was able to cast skins for less than $20/each. However, silicone is much more "sticky" than the oil impregnated nastiness of the TraumaMan skins, so you'll have to have the learners "lube" either their fingers or the incision with some sort of liquid gel or "blood" so there is less friction between the glove and the silicone.

Note: If you cast the entire thing in a medium softness silicone (10A to 15A) the thicker portions where the learner will be puncturing will be VERY tough with the density of flexed muscle and learners will tend to cut larger holes in order to fit their fingers in (This isn't entirely unrealistic tactile wise, but destroys the skin much faster than normal). I wouldn't use any silicone harder than 10-15A.

The corners of the casting will need a perforation to anchor onto the TraumaMan. If you use a low strength silicone for casting, you can reinforce these corners with nylon mesh.

Optional Modifications.
1) If you want to improve tactile fidelity and durability of your skins, you could go the simple route and use a more flexible but still strong but expensive silicone like DragonSkin Fx Pro (Hardness 2A). However, I think the best compromise is to use two silicone mixes, especially if you are already going to the trouble of using two separate color pours to match the colored layers of the original trauma man skins. For your initial pour (corresponding to the red portion of the trauma man skins) you would fill the two wells with a either a very soft and flexible silicone like Ecoflex 00-20 or use a regular medium silicone mixed with "Slacker" (a silicone additive that adds "squishiness", Link: https://a.co/d/4velQaE). These deeper sections aren't needed for the structural integrity of the skin, so a really soft and squishy silicone can add realism without compromising strength. For your second pour (corresponding to the visible external skin-colored portion of the casting), you would use a much more durable and harder silicone (Dragon Skin 10, or another 10-15A silicone) to act as the "skin".

2) If bleeding is really important to your simulation and you are willing to do extra work to build this in, I've also made a version with channels in the mold to add a run of IV tubing to allow this. You will need to add an extra step while doing the pour of the red portion, stopping in the middle once the silicone is partially cured to add a ziplock bag connected to IV tubing. (check beforehand to ensure your specific type of bag and tubing will not inhibit your silicones curing process). Once the bag is in place, slowly pour the rest of the red portion of the silicone to fill the two wells. Afterwards, you can pour the skin-colored portion normally. Once the entire skin has completed curing and has been demolded, you can use the IV tubing to fill the ziplock bags with simulated blood (or after initial puncture to pump blood in to simulate bleeding).

If you have any questions, please direct any inquiries to [email protected]

Part Print List:
Standard Mold:

• Part 1_V5
• Part2_V5
• Part3_V5
• Part4_V5

• Part5_V5

  Mold with Bleeding Channels:

• Part 1_V5
• Part2_Bleed
• Part3_V5
• Part4_Bleed
• Part5_V5
• Bleeding Leak Preventer - Right (Print 2x)
• Bleeding Leak Preventer - Left (Print 2x)