Tutorials for Molding and Casting
Taking a prop that you’ve made and making a copy can be scary–but don’t worry, it can be pretty simple! Start with a small prop and make a one-part mold. Follow along in our tutorial videos in the playlist below to learn the full process of silicone molding and casting plastic resin copies.
For our molds, we tend to use Smooth-On products, since they are reliable and have a great variety of materials. Another company with mold products is TAP Plastics, who also has the great benefit of carrying plastic sheets for other cosplay needs. For finding silicone and resin suppliers in your area, go to your local pottery supply store. They sometimes carry molding supplies, or can at least point you in the right direction.
We recommend starting small with trial size kits of silicone and resin. The materials below link to the smaller kits sold on Amazon. These links help support Punished Props–thank you for using them! If you’re looking for larger size material containers, go straight to the company’s website.
Builds with Molding and Casting
Our prop and costume builds listed below include our molding and casting techniques. Most of our molds are one-part or two-part molds. Our most complicated build to date is the District 9 Rifle, which involved our first matrix mold. We later improved the matrix molding process for the Bleach Hollow Mask.
Bill and his good friend Nick Kettman of Modulus Props show you how to make brush-on molds and slush casts of their custom sculpted masks!
When a Mythbuster issues you a challenge, you rise to the occasion! Adam Savage needed a pair of visors for his ACES space suit costume for his NYCC 2018 incognito costume. Bill and Britt got to work using their brand new vacuum forming machine.
Bill has put together several Bladerunner blaster kits and decided it was finally time to make his own from scratch. This 3D modeled and printed prop was molded and cast to make a highly detailed, custom replica… with a twist!
Creating a two part silicone mold can be an incredibly useful technique for prop and costume making. In this video Bill goes over the process using a hand cannon prop from Destiny as an example.
We’ve done pewter casting in the past, but we’re really starting to get a lot better at it. Check out our new, improved techniques PLUS some testing with lower heat resistance silicone.
Epoxy can be a great material for casting lightweight props out of silicone molds. Follow along as Bill gives a new material and technique the old college try!
Take a trip down memory lane as Bill shows off some of the first silicone molds he made over 5 years ago. Learn from his mistakes as he critiques those molds and compares them to newer ones he’s made after years of practice.
Bill dives into some legit metal casting using a high temp silicone and low melt metal. He’s also joined by Evil Ted! Follow along as they learn how to cast pewter along with the help of the amazing makers in the Twitch chat, the PropTarts!
On this live stream, Britt digs up the old shield coaster molds Bill made. Glow-in-the-dark, metal, and glitter powders are used to cast three unique coasters!
Bill made his own Fallout 4 Mister Handy scale model! The replica prop figurine was modeled in Fusion 360, printed and then molded and cast. Several light layers of paint were applied to get that Fallout metal look.
Britt and Bill made a prop Hearthstone Box! This build involves 3D Printing, lots of sanding, fake wood grain, molding and casting, box building, and metallic finishes.
Britt casts Hearthstone symbols with glow powder, metal powder, and sparkles! The Punished Props shop is now contaminated with glitter.