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.
- Mold Release – For multi-part molds
- SO-Strong Tint – Add colors to resin
- Plastalina Clay – Block off silicone
- Thi-Vex – Silicone Thickener
- Plastipaste II – For a quick mold jacket
- Fiberglass Mat – For fiberglass mold jacket
- EpoxAmite – Combine with Fiberglass Mat
- EpoxAcoat – Brush on layers over EpoxAmite
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 molds and casts several pieces of Rey’s Blaster using silicone and urethane resin.
Punished Props made a version of Ichigo’s Hollow Mask from the Bleach series!
In this episode of Prop: 3D, Brittany models the Amulet of Talos from Skyrim! We show you how to mold a 3D print and cast a copy in real metal!
In this episode of Prop: 3D, Bill shows you how to model and print a visor as well as how to mold and cast a durable vacuum forming buck!
Bill and Britt modeled, printed, molded and cast a Nuka Cola Rocket bottle from Fallout 4. Check out how it’s done.
Follow along as Britt casts some kits from really old molds… what could go wrong?
Punished Props live streamed for 16 hours as they worked on Destiny Lord Shaxx and Vex Goblin costumes for PAX Prime and DragonCon!
Here’s my replica prop build videos for the District 9 Rifle!
Bill takes you through all his steps to build this replica prop bow from Rise of the Tomb Raider!
Silicone ain’t cheap. That’s a fact of life.
For the Kaijudo Gauntlet build, I used all Smooth-On products.
Check out this build for the Kaijudo Gauntlet prop replica trophies I made for Wizards of the Coast!