How to plastic coat foam costume pieces

[Megatron]

easy sanding means it has talc in it most likely and likes to crack when flexed. Body fillers with hair like fibers will be stronger and more flexible.

 

[7sinzz]

Interesting thoughts megaton. I will look into that.

 

[7sinzz]

3 coats later and I did a small test with my thumb nail to find that it doesn't require much pressure to go through at all. Xrobots could you confirm the same findings on your test piece? I'm thinking between 7-10 coats is probably going to be required.

 

[Megatron]

You know what you are trying to do is make a composite.
Maybe look into aircraft spruce website. They sale foam composite kits and have lots of info on it.

ok guys I did some research for you..
you could try to switch foams if you want stuff to stick. Try using pvc foams.
http://www.micromark.com/Curvable-P...-x-18-Inches-x-3mm-1and8-Inch-Thick,8934.html
http://www.aircraftspruce.com/catalog/cmpages/divinycellfoam.php
http://www.mcmaster.com/#pvc-foam/=k3l4j8

I did find this cool site on eva foam
http://www.schenz.com/fm_eva.html

FOAM...
http://www.mcmaster.com/#foam/=k3l73b

oh and another cool product we used at Disney, wonderflex
http://www.wonderflexworld.com/

 

[7sinzz]

So, as opposed to bonding to create one thick layer of plastic, I'm actually creating many brittle layers? Makes sense. I'm hoping it will still increase the strength. Pushing a pair of scissors through 1 sheet of paper is considerably easier than pushing it through 10.

 

[billymaya]

well there must be logic behind it although i do wonder why your layers are peeling as you sand it did you give the 65 D a light sanding between coats wonder if they would help with the peeling so the next layer bond to it more and becomes one with it. also you might be laying in on to thin perhaps, maybe try putting it on a bit thicker? ive never used the stuff so im only guessing

 

[GammaGreen]

Much easier way to do this is with :

CHICAGO LATEX PRODUCTS

Rigid casting latex - #501 - Rigid casting material

Slushes and brushes like latex. Once it hardens it's as hard as stone, sandable, paintable, and still bends. Takes all rattle cans and even chrome paint.

 

[Megatron]

Much easier way to do this is with :

CHICAGO LATEX PRODUCTS

Rigid casting latex - #501 - Rigid casting material

Slushes and brushes like latex. Once it hardens it's as hard as stone, sandable, paintable, and still bends. Takes all rattle cans and even chrome paint.

Stay far away from natural latex...
It rots, and many things make it react.. no fun at all.

Now as for neoprene, its a man made rubber, wet suits are made from it. And you can buy it in sheets already. This is like going back to platidip.

 

[Megatron]

So, as opposed to bonding to create one thick layer of plastic, I'm actually creating many brittle layers? Makes sense. I'm hoping it will still increase the strength. Pushing a pair of scissors through 1 sheet of paper is considerably easier than pushing it through 10.

Two things cause composites to be brittle, type of matrix (resin or epoxy) and using to much. the fiberglass makess it strong, the matrix is what bonds it.

If you are doing so many layers of plastic why not add a layer of fiberglass or something.

There are no shortcuts guys. It will be time, money or strength. And sometime all three. The aerospace industry has been using this stuff for over hundred years. Some of the first planes used cloth and dop (resin).

Layer separation can be because the core is flexible and the outer coat ridged.

 

[GammaGreen]

Stay far away from natural latex...
It rots, and many things make it react.. no fun at all.

Now as for neoprene, its a man made rubber, wet suits are made from it. And you can buy it in sheets already. This is like going back to platidip.

It's not natural latex. I've used this method for several costumes and it works very well.

 

[Megatron]

It's not natural latex. I've used this method for several costumes and it works very well.

I know...
might as well use a hard urethane rubber-smooth on sales some very hard rubber too

 

[GammaGreen]

except urethane is a lot harder to paint. not impossible, but much harder and resistant to sanding. the rigid latex is much easier than mixing a two-part solution and worrying about smoothing. but hey...different strokes.

 

[winterg]

Thank you very much for this thread. I've yet to try a foam build because most of the ones I see you can obviously tell that it is a foam build. But you get a gorgeous surface with your method. I am excited to give it a try now.

 

[patriot109]

How much 65d is needed to do a whole iron man suit?

 

[jeffreygullett]

I got the gallon kit and used about half of it.

 

[7sinzz]

Jeff, what's the rigidity like?

 

[patriot109]

Oh well that's good news haha

 

[Kiarou]

I'm planning on building a Samus suit using this method
Does anyone know exactly what type of foam is best? I was thinking of just getting some 6mm foam from my local craft store, but it looks like I might need a thicker type of craft foam.
I guess my real question is, how much foam on a rough estimate, did you guys use for your iron man suit? 30-40 sheets? I'm not sure, I'm just trying to get the best cost estimate.
Also, I was planning on using Flexbond (07500 0128 - Flexbond - 1 Gallon - StageStore.ca - your Canadian source for Theatrical Supplies) for the glue agent instead of PVA

Any sort of direction on this would be awesome, thanks!

 

[ironman wanabee]

awesome

 

[torx]

any new pictures or updates utilizing this plastic coating process?