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Mold-making and Casting

3D Printing Cosplay & Props Electronics Mold-making and Casting Star Lord

Star Lord Earpiece Revisited

By on July 31, 2017

A few years ago, right after the debut of the first Guardians of the Galaxy film, I banged together a simple 3D model for Star Lord’s earpiece in Sketchup,…

Cosplay & Props Mold-making and Casting Titanfall

Coating with UreCoat

By on May 29, 2017

I tried something a little different this afternoon. When I was at MakerFaire NYC last year, one of the Smooth-On reps was kind enough to give me a sample…

Cosplay & Props Mold-making and Casting Titanfall

Filament to foam: Molding flexible parts

By on May 28, 2017

I bounce around on projects (at least, on personal projects) so it’ll probably come as no surprise that I switched gears the last few days. One of the many…

3D Printing Cosplay & Props Mold-making and Casting Titanfall

Revisiting the Data Knife design

By on May 21, 2017

Alllllright. I haven’t updated this in a while. My excuse is that I have been working a lot, and also I just bought a Chinese K40 laser cutter/engraver that…

3D Printing Cosplay & Props Immortan Joe Mold-making and Casting

Printed fittings and pulled forms!

By on July 26, 2016

The printed right-angle pipe fitting seems to have worked out pretty well, all things considered!

I need to sand it a bit, glue the parts together, then XTC-3D the whole…

Cosplay & Props Immortan Joe Mold-making and Casting

Hydrocal arms and air filter intakes

By on July 25, 2016

Molds were made up for the arm bucks using Smooth-On’s Rebound 25 mold rubber and backed with some old Onyx Fast resin I had that I had to get…

3D Printing Cosplay & Props Immortan Joe Mold-making and Casting

Improving the master casts

By on July 24, 2016

We spent a good bit of time last night lengthening the master copies of each of these things out with monster clay to fit my apparently-freakishly-long arms.

Figured it’d be…

3D Printing Cosplay & Props Immortan Joe Mold-making and Casting

Early Arm Prototyping

By on July 22, 2016

Overall results look good so far. We did a little experiment today – I made a rubber mold of one of the arms, then made a hydrocal copy of…

3D Printing Cosplay & Props Immortan Joe Mold-making and Casting

Forearms for arms!

By on July 16, 2016

One of the things we’ve been working on in the background is the rest of the armor that has to be heat-formed. The bicep armor looks pretty straightforward, as…

Cosplay & Props Immortan Joe Mold-making and Casting

Torso now twice as fun!

By on August 30, 2015

Maria took the back of the roman armor and some Apoxie Sculpt and added some extra bits so we had something to form Joe’s weird back musculature over.

As before,…

3D Printing Immortan Joe Mold-making and Casting

Lessons in Thermoforming

By on August 20, 2015

Finally made forward progress on the breastplate that wasn’t super duper frustrating.

So I am using PETG sheeting in 1/16″ thickness. That’s .060″ thick, for reference. I saw TheRPF.com forums user…

Cosplay & Props Immortan Joe Mold-making and Casting

Molding Immortan’s Mask, Part 2

By on August 14, 2015

My mask had some extra-scary work done. I used a scrollsaw to cut an MDF divider for the mask and bolted it together so I could start making the…

Cosplay & Props Immortan Joe Mold-making and Casting

Molding Immortan’s Mask, Part 1

By on August 10, 2015

I’m mostly just monkeying around and doing what I see other people do when it comes to making these molds. I hope I understand the process right, but I…