Advice For Molding A Large Body Sculpt?

[yodasmeagol]

Hey all. I am planning to build a large monster costume. I will sculpt the pieces from clay and the final product will be a latex suit. My question is what would be the best way to mold my sculpted pieces?

I'm thinking of using traditional 2-part plaster molds, probably a process similar to this, for sculpting and molding:
http://www.thehunter..._25#entry162334

And then making latex casts like this:

However, I'm planning for what would be considered a very restrictive budget for this type of process. So I'm looking to be as economic and thrifty as possible. Here are possible thoughts I've had:

I could sculpt the entire torso/arms/legs all at once, but that could require dozens of pounds of clay. I'm thinking I would sculpt the legs, torso, and arms all in separate pieces. I could reuse clay, and could be simpler to manage the physical space.

Another issue is dividing walls for the 2-part molds. If I have a leg sculpted, I could lay it down horizontally and then build a clay dividing wall, which would have to be supported by something else on the underside. I'm wondering if there's an easier way to do these walls, such as with a thin shim instead. Or ways I could make a one-piece mold? Could resin be used for the molding process in some way, to lessen weight and cost of plaster? Or any general way to make the dividing wall more simply, without using a ton of clay?

Are there other alternatives for this kind of process I could consider? Does anyone have an estimate as to how many pounds of clay would be used in a torso sculpt? Any advice would be appreciated. Even just general tips on how to mold a large object.

 

[seahunterr]

Plaster is going to be a back-breaker....if you have a few people to help you then it's an option. All the other options are expensive. If you try to go light on the plaster the molds will crack.

 

[afedorniak]

hi there,im doing a full p2 body sculpt and im going to mould it with fibreglass as i want a silicone full body suit. my thoughts this would be lighter to handle when casting! this is a 12- 18 month project im doing! good luck with what you decide dude!!

 

[carss66]

fiberglass was my option,light and strong.plaster would be too heavy and not an option for my needs.

 

[yodasmeagol]

Fiberglass did seem like a good option. Any recommendations (or links to discussions) about what kind of resin I could use would be helpful. I can find tons of discussions about casting with resin, but very few about molding. Would there be any difficulties in putting resin on a clay sculpture? Would I need a special type of mold release?

I've also heard about people mixing Bondo filler with resin for this kind of thing. Anyone have experience with that?

 

[MEANGENE83]

There are epoxy resins that do not smell and are relatively non-toxic. These resins can be used to make molds and can used with re-inforcing fiberglass mesh.

The term "fiberglass" is thrown around a lot in reference to Polysester resins i believe. (hope i am not mis matching the two?) Do a little google research. I will see if i can dig up my old links.


The video you posted above was made by me, as were the molds. They weigh a ton. I made them knowing full well they would. I did it becuase the bags of ultracal30 were cheap and could be purchased locally. I REGRET IT 1000%. Such a pain having these things. Like boat anchors.

Epoxy resins will be my mold material of choice from now on.... Latex is not meant to dry in a resin mold of any kind. But you can force dry it with heat and do it in layers. Slower process but the molds are definitely lighter.


Mold Release: should be used anytime you mold anything. Its main purpose is to make it easier to remove the clay from the mold. So why not make it easier. Some things technically "dont need any release agent" ie. silicone. But why not go the extra mile.
Stan Winston studio school has a 20$ online youtube video on molding with ultracal30. Now even though you are not molding with Ultracal30, 50% of the video shows the same methods we use for ALL our molds, regardless of material. WATCH THE VIDEO!!!!! 20$ to indefinitely be able to watch the streamed class episode. If you dont watch it your an idiot.

I could type all day and still not get across half the methods you are asking about. IE "Shimmed mold walls". They show that perfectly on the episode.
Feel free to contact me directly if you need further assistance, I am no expert but I know where to find the answers usually.

 

[seahunterr]

Hmmm, I need to watch that video....

 

[propsculptor]

As an experienced Special Make-up Effects Artist I completely agree with MEANGENE83, I understand for many these projects are done on extremely tight Budget but IF this was done in any kind of Plaster the weight would limit you a lot!

Fiberglass Molds (Or Epoxy that doesn't smell) are exactly what I would suggest, even if you have to take your time learning how to use them, or wait for someone experienced to help guide you, a project as involved as this is worth doing right the first time!