Cosplay Tutorial: Iron Man Helmet Casting

Тәжірибелік нұсқаулар және стиль

In this mold making how to video, we demonstrate how to make a lightweight and durable epoxy fiberglass support shell (also called a mother mold or jacket) using the EpoxAmite laminating epoxy system. We then cast this mold by hand rotating (or slush casting) Smooth-Cast 57D impact-resistant urethane resin. Just how durable is Smooth-Cast 57D? Jump to 17:13 to see a 30ft drop test.
In Part 1 we demonstrated how the Rebound 25 silicone glove mold was made for this project: • Cosplay Tutorial: Iron...
EpoxAmite laminating epoxy: www.smooth-on.com/product-lin...
Smooth-Cast 57D urethane plastic: www.smooth-on.com/products/sm...
Adult Supervision Required
Keep Out Of Reach Of Children
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Make It Now! with Smooth-On
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Пікірлер: 151

  • @paisley436
    @paisley4365 жыл бұрын

    Thanks for your help today Milo! You're correct, this video was very helpful.

  • @smoothon

    @smoothon

    5 жыл бұрын

    Thank you for watching!

  • @ericprint3576
    @ericprint35762 жыл бұрын

    This video started me off into mold making and casting each mold I've made has had improvements from small things I've noticed when casting.

  • @smoothon

    @smoothon

    2 жыл бұрын

    Great to hear!

  • @Viridisdaemonis
    @Viridisdaemonis2 ай бұрын

    This products are truly amazing! Well done to the the whole team. I've purchased some products for my own sculpted masks. Thx!

  • @smoothon

    @smoothon

    2 ай бұрын

    That is wonderful to hear and thank you so much! I hope the masks turn out awesome!

  • @vincentb2175
    @vincentb21754 жыл бұрын

    Wow! Great work, very impressive.

  • @JOEGGGJOE
    @JOEGGGJOE6 жыл бұрын

    Very impressed with the impact resistance test. That was awesome.

  • @smoothon

    @smoothon

    6 жыл бұрын

    Thanks for watching!

  • @aflah4863

    @aflah4863

    4 жыл бұрын

    @@smoothon where can i get the mold of the helmet?

  • @aflah4863

    @aflah4863

    4 жыл бұрын

    @@smoothon how to buy this mold

  • @bryansiepert9222
    @bryansiepert92224 жыл бұрын

    One important reason why to use the 57D for roto casting that you didn't mention: It doesn't snap cure! I make the mistake of trying to roto cast with 300 and let's just say it didn't work so well! It ended up being super lumpy and uneven because it went from flowing around the mold to all stuck in one corner in very short order! Switched to 65D which also isn't snap cure and it worked like a charm :)

  • @smoothon

    @smoothon

    4 жыл бұрын

    Excellent point!

  • @boujme3457
    @boujme34575 жыл бұрын

    Your product is great, we want a course about manufacturing diving fins, boots and carbon feathers, thanks

  • @riyawandwinugroho1277
    @riyawandwinugroho12772 жыл бұрын

    Thank you for this amazing tutorial..

  • @smoothon

    @smoothon

    2 жыл бұрын

    Thank you for watching! Don't forget to subscribe!

  • @JoseLuis-tn5qi
    @JoseLuis-tn5qi4 жыл бұрын

    How you can work with the fiber glass without gloves? I cant do that without my hands itching :/

  • @volcheq2041
    @volcheq20412 жыл бұрын

    Thank you for the content!

  • @smoothon

    @smoothon

    2 жыл бұрын

    Thanks for watching! 😃

  • @jansieber1503
    @jansieber15035 жыл бұрын

    How much material of each kind did you use for the project?

  • @mattnudds1258
    @mattnudds12585 жыл бұрын

    Can you just use fiberglass and the resin at autozone to make the support shell?

  • @rodiantorres5656
    @rodiantorres56565 жыл бұрын

    amazing tutorial as always! can you also make a tutorial video on how to cast and mold chest armor, fore arms and leg pieces? would appreciate that a lot. thanks guys!

  • @smoothon

    @smoothon

    5 жыл бұрын

    Great idea Rodian, we will let the video team know.

  • @candidate17

    @candidate17

    5 жыл бұрын

    This! I'm glad someone asked

  • @littlewiihacker
    @littlewiihacker4 жыл бұрын

    What grit sandpaper did you use?

  • @dr-onestuffido
    @dr-onestuffido5 жыл бұрын

    Wow! fabulous video and so helpfull thank you :) If youve done with the mould I wouldnt mind a cast from it I have to admit :)

  • @michaeladams5340
    @michaeladams53404 жыл бұрын

    Could you show a video of making Halo Mjolnir Mark 1 Armor?

  • @ReneeNme
    @ReneeNme6 жыл бұрын

    I have a life size rotocast 1989 Michael Keaton as Batman bust coming and I'm all new to the art of rotocasting. It's just so fascinating.

  • @smoothon

    @smoothon

    6 жыл бұрын

    Sounds cool! Thanks for watching!

  • @ReneeNme

    @ReneeNme

    6 жыл бұрын

    Question: My bust was cast rather thin and would like to thicken up the facial area before proceeding to fine tune it. The bust was made using Quickcast by SilPak. Should I be okay as far as compatibility if I build up the facial area using Smooth Cast 65D ?

  • @smoothon

    @smoothon

    6 жыл бұрын

    It can be difficult for urethane resin to bond to itself if it is more than a day or so old. If you send our tech team a ticket, they can give you more options: www.smooth-on.com/support/

  • @ReneeNme

    @ReneeNme

    6 жыл бұрын

    Thanks. I submitted a ticket to tech support. Hopefully they'll have an idea or two.

  • @ReneeNme

    @ReneeNme

    6 жыл бұрын

    Wow !!! Sent a ticket and received a response in only 9 hours from Chris ( Material Specialist ). Impressive. His recommendation, after prepping the area I need to thicken, is Plasti~Paste II.

  • @drsmiff777
    @drsmiff7776 жыл бұрын

    how much 57D per cup are you using?

  • @PANDANIKEFOOTBALL
    @PANDANIKEFOOTBALL5 жыл бұрын

    Thank you for such a cool lesson! Please tell me how many pieces of plastic castings can withstand this form of silicone rebound25?

  • @smoothon

    @smoothon

    4 жыл бұрын

    Check out this FAQ for more info - www.smooth-on.com/support/faq/183/

  • @vedasvirtue5571
    @vedasvirtue55712 жыл бұрын

    Awesome videos, I'm going to be doing this for the first time soon and this is incredibly helpful. Just had a question, I noticed the helmet after the casting has a little bit of a texture to it? I will likely be sanding afterward anyways, but I was wondering if there's a better way to smooth it while applying the silicone process?

  • @smoothon

    @smoothon

    2 жыл бұрын

    Some people use 99% isopropyl alcohol when smoothing the silicone.

  • @janzumkley6897
    @janzumkley68975 жыл бұрын

    Hey nice video💪 helps alot. Would it be possible to use polyester resin instead for the second mold? Thanks for your help💪

  • @smoothon

    @smoothon

    5 жыл бұрын

    Absolutely. Many moldmakers use polyester resin and fiberglass for support shells.

  • @dreroelandt2246
    @dreroelandt22463 жыл бұрын

    hello! I was wondering if there was a resource to go more in depth about the bolting of the piece- for instance, is there a reason the bolts are added after the piece has been demolded the first time?

  • @smoothon

    @smoothon

    3 жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @jerrybatacas
    @jerrybatacas6 жыл бұрын

    nice, just one question, what will be cheaper, use this epoxy or plastipaste to the mother mold?

  • @smoothon

    @smoothon

    6 жыл бұрын

    This method has a lower material cost, but takes a longer amount of time compared to creating a Plasti-Paste II support shell.

  • @akshaytilawane9068
    @akshaytilawane90683 жыл бұрын

    nice

  • @mtkuennen84
    @mtkuennen846 жыл бұрын

    Is there a way to glue to resin pieces together if one of mine broke a piece off?

  • @smoothon

    @smoothon

    6 жыл бұрын

    You can use super glue or epoxy to adhere the pieces together.

  • @Cezararteprojetos
    @Cezararteprojetos Жыл бұрын

    Show parabéns mais um inscrito

  • @smoothon

    @smoothon

    Жыл бұрын

    Thanks for watching! 😃

  • @perigosu8449
    @perigosu84495 жыл бұрын

    what if I'm making a half mask that has to fit semi-tight to my actual face (I want it made out of similar plastic). Do you have a tutorial for that?

  • @Cam80914

    @Cam80914

    5 жыл бұрын

    Check out Punished Props. They have a tutorial for making a mold for a Dragon Priest mask. They used Plasti-Paste for their jacket. It's a heavier product, but it cures much faster. I also have some experience using that product. For masks it really isn't bad at all.

  • @Deathbysnusnu125
    @Deathbysnusnu1252 жыл бұрын

    can you cast silicone using a slush method or would you get too many bubbles? maybe if you used a thinner?

  • @smoothon

    @smoothon

    2 жыл бұрын

    You could slush our Smooth-Cast 57D or 65D into the mold.

  • @hannahblock8984
    @hannahblock89843 жыл бұрын

    I am having and issue with the clay wall still sticking to the shell. I did use the release agent. Any other tricks to making removal easier?

  • @smoothon

    @smoothon

    3 жыл бұрын

    You could apply a thin layer of paste wax to the clay before you apply the release. That may help.

  • @ricosuave4275
    @ricosuave4275 Жыл бұрын

    Great video! I've been thinking of doing a full 3d printed Iron Man suit for a while now. Can you actually mould the entire suit using this process? I'm assuming its better to do it before painting and assembly or does it matter?

  • @smoothon

    @smoothon

    Жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @FreddyFX
    @FreddyFX3 жыл бұрын

    I'm a little puzzled. I see that with all the registration keys you've put on, you put the wider tapered and outward, which works great for locking in the silicone mold along the mother molds part line. But the keys on the left and right side of the helmet by all logic should be mechanically locked in when you fiberglassed over them. Yeah the flexibility would allow you to still separate them, but because of the tapered shape, I would think it would be almost impossible to reset The left and right side registration keys back up if you were going to do another pull. Is there something I'm missing?

  • @smoothon

    @smoothon

    3 жыл бұрын

    The rubber can be reset into the registration hole with the help of a small amount of baby powder applied to the rubber.

  • @seekertosecrets
    @seekertosecrets5 жыл бұрын

    A question about the fiberglass. You are suppose to wear gloves for this material, right? Is it any different to other makers Like 3M?

  • @smoothon

    @smoothon

    5 жыл бұрын

    You should wear gloves when handling fiberglass.

  • @nizam8979
    @nizam89794 жыл бұрын

    I'm curious. Can you brush-on the 57D instead of slush it around?

  • @smoothon

    @smoothon

    4 жыл бұрын

    Definitely

  • @KRGraphicsCG
    @KRGraphicsCG5 жыл бұрын

    I definitely want to do this with my face mask

  • @herv4851
    @herv48515 жыл бұрын

    HELLO ? WITH WHAT DO YOU DEGREASE THE PIECE BEFORE PAINTING IT. I HAVE PAINTED MY PIECE AND THE PAINTING HAS NOT TAKEN LOCALLY DUE TO SILICONE! THANK YOU FOR YOUR REPLY

  • @smoothon

    @smoothon

    5 жыл бұрын

    A wash with mineral spirits can help.

  • @mattnudds1258
    @mattnudds12585 жыл бұрын

    Is there anyway I can buy that glove mold and shell? I'd definitely be interested please let me know .

  • @smoothon

    @smoothon

    5 жыл бұрын

    We don't sell the molds, but can teach you to make your own! :)

  • @chevelle99xify
    @chevelle99xify5 жыл бұрын

    You need to make a helmet showing the gelcoat proccess for those of us who want it to come out heavy like a helmet would really feel !!!!!!

  • @kenyonhope879
    @kenyonhope8793 жыл бұрын

    i cant find the glass cloth anywhere on your website. where can i get it?

  • @smoothon

    @smoothon

    3 жыл бұрын

    You can contact your nearest Reynolds Advanced Materials branch for pricing on this glass cloth: www.reynoldsam.com/location/

  • @aaronli1540
    @aaronli15403 жыл бұрын

    Hi there, I want to cast a helmet that I made from scratch and is there a way where you can help cast this helmet and make a duplicate version?

  • @smoothon

    @smoothon

    3 жыл бұрын

    Hi there! This is a good question for our tech support team, can you send them a ticket here? www.smooth-on.com/support/ticket/add/agree/ Thanks for watching!

  • @samscreativeally1528
    @samscreativeally15285 жыл бұрын

    do you ship this materials to the phils.? I have a cool project here a predator motorcycle helmet and my plan is to do this as a small business of mine.

  • @smoothon

    @smoothon

    5 жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @skyrider4789
    @skyrider47892 жыл бұрын

    Can carbon fiber be used instated of fiber glass cloth?

  • @smoothon

    @smoothon

    2 жыл бұрын

    Yes it could.

  • @manuelcalle6506
    @manuelcalle6506 Жыл бұрын

    Can you also fill the mold with rigid polyurethane resin?

  • @smoothon

    @smoothon

    Жыл бұрын

    Yes you could.

  • @user-kl9tw7ti5e
    @user-kl9tw7ti5e10 ай бұрын

    Are you able to reclaim the clay used in this process? Is it contaminated by the release agent? Is there a chance re-used clay would cause cure inhibition if used in future molding projects?

  • @smoothon

    @smoothon

    10 ай бұрын

    There is a chance that residue may cause an issue. If you were to retain the clay, it would be best to use it in non crucial applications such as mold walls.

  • @seekertosecrets
    @seekertosecrets5 жыл бұрын

    I have another question about the process. Can the cast be given a shine using a 3 stage painting process? Like using a black gloss coat, painting it with acrylic paint and finished off with clear gloss paint?

  • @smoothon

    @smoothon

    5 жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @seekertosecrets

    @seekertosecrets

    5 жыл бұрын

    Okay, I just sent a tech ticket.

  • @baljazz
    @baljazz3 жыл бұрын

    How do you do this but with with a full silicone mold

  • @smoothon

    @smoothon

    3 жыл бұрын

    Hi there! This is a good question for our tech support team, can you send them a ticket here? www.smooth-on.com/support/ticket/add/agree/ Thanks for watching!

  • @andreprieto8916
    @andreprieto89163 жыл бұрын

    Does this resin also work with carbon fiber parts?

  • @smoothon

    @smoothon

    3 жыл бұрын

    Yes, EpoxAmite resin will work with carbon fiber.

  • @ragztv4927
    @ragztv49272 жыл бұрын

    What is better material to make helmet? epoxy resin Or fiber resin?? Thnka sir🙏

  • @smoothon

    @smoothon

    2 жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @p2studio807
    @p2studio8072 жыл бұрын

    how buy Smooth-Cast 57D in thailand?

  • @smoothon

    @smoothon

    2 жыл бұрын

    Thanks for watching P2 Studio. You can find a full list of Smooth-On distributors here - www.smooth-on.com/distributors/

  • @rdgk1se3019
    @rdgk1se30196 жыл бұрын

    Does that glass cloth make your hands itch?.......also I would like to see a Voltron sword.

  • @smoothon

    @smoothon

    6 жыл бұрын

    Thanks for the suggestion - this cloth is 'soft' unlike chopped strand mat, but you should still use gloves when handling it.

  • @lawsongangster
    @lawsongangster5 жыл бұрын

    mark 1 iron man helmet

  • @xxxxzorroxxxx
    @xxxxzorroxxxx6 ай бұрын

    Can I use this to make rubber tires 57D

  • @smoothon

    @smoothon

    6 ай бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @seekertosecrets
    @seekertosecrets5 жыл бұрын

    Another question came to mind about this video. Can this resin be sanded, cut or drilled after the casting is complete?

  • @smoothon

    @smoothon

    5 жыл бұрын

    Yes, it can be sanded, cut and drilled

  • @snakeeyes037

    @snakeeyes037

    2 жыл бұрын

    @@smoothon can this resin stand up to uv rays, heat and humidity?

  • @smoothon

    @smoothon

    Жыл бұрын

    This resin is not UV resistant unless it is painted. Humidity will not affect it, but high heat may soften it.

  • @johnmoore2344
    @johnmoore23446 жыл бұрын

    Can you do a Batman Body suit in segments like the helmet?

  • @smoothon

    @smoothon

    6 жыл бұрын

    Thank you for the suggestion. We can see about adding a project like this to the roadmap. In the meantime, if you would like to discuss a project like this with a support technician feel free to reach out at www.smooth-on.com/support/ticket/add/agree/ .

  • @KurtisJoseph
    @KurtisJoseph9 ай бұрын

    So this stuff is firm enough to cast helmets yet will flex enough to put on.... I wonder if it would work for a Batman cowl then? Is it urethane or resin? I had no idea resin had any flex at all.

  • @smoothon

    @smoothon

    9 ай бұрын

    This is a semi-rigid urethane resin. Many of our customers who make cowls use our Vytaflex series of urethane rubber: www.smooth-on.com/product-line/vytaflex/

  • @KurtisJoseph

    @KurtisJoseph

    9 ай бұрын

    @@smoothon thanks! I need to talk to some associates about getting stuff for brush on molds too.

  • @jansieber1503
    @jansieber15035 жыл бұрын

    Any Idea how much Clay would be needed?

  • @lasarith2

    @lasarith2

    5 жыл бұрын

    Probably about 6-7 of the sculptex

  • @KevinReillySV
    @KevinReillySV4 жыл бұрын

    Does a trial size work for one helmet?

  • @smoothon

    @smoothon

    4 жыл бұрын

    It would depend on the size of the helmet. We have some calculators which may help: www.smooth-on.com/support/faq/52/

  • @UnexpectedAuto
    @UnexpectedAuto6 жыл бұрын

    would like to learn how to do a matrix mold

  • @smoothon

    @smoothon

    6 жыл бұрын

    We have a turtorial for that here - www.smooth-on.com/tutorials/creating-cavity-pour-mold-mold-max-30/

  • @j.danaclark89
    @j.danaclark896 жыл бұрын

    Very very cool. I just wish I could afford you stuff.

  • @smoothon

    @smoothon

    6 жыл бұрын

    Thank you for watching!

  • @orlandofontanez1687
    @orlandofontanez16875 жыл бұрын

    Can you make a batman Cowl mask with the same kit

  • @smoothon

    @smoothon

    5 жыл бұрын

    You could use a similar process to make a Batman cowl.

  • @AbdullahKhan-yj5lz
    @AbdullahKhan-yj5lz4 жыл бұрын

    But how could I make the mold without an actual helmet

  • @TheRobmcknz

    @TheRobmcknz

    3 жыл бұрын

    You have to have a master to create the mold. For example: you could 3D print the helmet, sand it smooth and use that as your master.

  • @stickman787
    @stickman7872 жыл бұрын

    IM getting some of that 57d....

  • @smoothon

    @smoothon

    2 жыл бұрын

    It's amazingly strong resin!

  • @Meyvn08
    @Meyvn084 жыл бұрын

    Do Jason Todd Red hood helmet

  • @PrayerIsMyHabit
    @PrayerIsMyHabit Жыл бұрын

    How much would a process like this cost to replicate

  • @smoothon

    @smoothon

    Жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @jimmahbee
    @jimmahbee Жыл бұрын

    Can you do the body armor?

  • @smoothon

    @smoothon

    Жыл бұрын

    This is a great idea! We will forward it to our video team.

  • @didiermolina3909
    @didiermolina39093 жыл бұрын

    Can you sand this material?

  • @smoothon

    @smoothon

    3 жыл бұрын

    EpoxAmite resin can be sanded once cured, a suitable dust mask must be worn.

  • @mineurbiz
    @mineurbiz5 жыл бұрын

    I would like to see a video making a mold of a motorcycle seat, then reproducing it with 7 FR foam. I am restoring a bike, that they no longer make the foam or plastic pan for, I have another bike that I can make a mold of its foam from, just would like to see a video of your suggested process.

  • @smoothon

    @smoothon

    5 жыл бұрын

    Thanks, this is a great idea!

  • @mineurbiz

    @mineurbiz

    5 жыл бұрын

    Cool, I hope that you make a video of it, I could really use the help.

  • @PizzaOignonGaming
    @PizzaOignonGaming4 жыл бұрын

    i buy !

  • @janzumkley6897
    @janzumkley68975 жыл бұрын

    I decided to use epoxy as well, but can you tell me what kind of fiberglas you use. Esspecially the g/m2 and the Type of fiberglass?💪 Thanks for your help again . Very very cool Tutorial!

  • @smoothon

    @smoothon

    5 жыл бұрын

    Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

  • @flexiwing4450
    @flexiwing44505 жыл бұрын

    Hi great tutorial i need little suggestion plz reply

  • @smoothon

    @smoothon

    5 жыл бұрын

    What can we help with?

  • @flexiwing4450

    @flexiwing4450

    5 жыл бұрын

    @@smoothon thanks can we use basic fiber mesh for this purpose, i known it is not as dense as your fabric but can we use basic mesh with 3 times more layers?

  • @flexiwing4450

    @flexiwing4450

    5 жыл бұрын

    @@smoothon fiber mesh used for water proofing

  • @smoothon

    @smoothon

    5 жыл бұрын

    You would have to test this for performance independently.

  • @flexiwing4450

    @flexiwing4450

    5 жыл бұрын

    @@smoothon so it mean it ll work but strength & performance might suffer?

  • @mykalimba
    @mykalimba5 жыл бұрын

    Looks like a bloodbath at 9:55. I assume this is the epoxy reacting to the mold release agent?

  • @smoothon

    @smoothon

    5 жыл бұрын

    Hello! The epoxy is dyed with SO-Strong red so you can easily see where you need to apply the cloth. :)

  • @abdonafea4911
    @abdonafea49116 жыл бұрын

    HOW CAN HAVE THIS MATRRAIL IN EGYPT

  • @smoothon

    @smoothon

    6 жыл бұрын

    Check out our distributors list here: www.smooth-on.com/distributors/ Thank you for watching!

  • @driversteve9345
    @driversteve93456 жыл бұрын

    All we need to do now is make it bullet proof and install a 3D like lcd screen in the eyes! LoL!

  • @smoothon

    @smoothon

    6 жыл бұрын

    That would be great! Thanks for watching!

  • @h.radican
    @h.radican5 жыл бұрын

    HQ!

  • @smoothon

    @smoothon

    5 жыл бұрын

    Thank you for watching!

  • @amirulmukmin4965
    @amirulmukmin49655 жыл бұрын

    try mold and cast a sword

  • @smoothon

    @smoothon

    5 жыл бұрын

    Good idea, thank you for watching!

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