Making a Chipotle Pepper

First, I convert Chipotle’s logo to vector with Illustrator:

I tried to make a nice smooth design in Blender:

Onto the machining:

Adaptive Clearing 1/4 (Remove large chunks):

Pocket 1/8 (Remove big chunks that Adaptive couldn’t):

Contour 1/16 (follow the detailed contour of the pepper):

Pocket 1/16 (clean the islands left over by contour and make detailed snapping holes):

My first try molding didn’t work well because I used materials that were a little too old and I mixed them for too long, so that the mixture became too hard and didn’t let bubbles rise. Here’s results from my second try:

The process:

The result: