Adam Savage Attempts Spray Casting Props! 

Learn more about FBFX’s work at www.fbfx.co.uk/

i love that Adam has enough basic knowledge of the process to ask questions that make sense and are not completely basic. His enthusiasm is infectious.

It would be so cool to see Adam finish the surface/weather of one of those.

Adam walks into a shop he's never been in before, using materials he's never touched before, and ends up being 80-90% successful on the first try. That's an example of "transferable general skills" right there. :)

No word of a lie, I worked for these guys 20 years ago in their old workshop. Had a summer job while I was at Uni and worked on Troy. Hands down the best job I ever had and the ber firm I ever worked for. Was lucky enough to go back to them a few times to work. 20 years on and still miss it

I love the Last couple of videos where Adam does things he's never tried before. It's like one day builds but with the enthusiasm of teenage Adam lol.

you can tell my man is used to getting those done fast, no time to waste letting Adam figure out how to get them out of the molds lol

Those powered air-purifying respirators are the absolute bees knees, kinda surprised Adam hasn't used them before. I just couldn't work without them anymore personally.

Adam's excitement is so infectious!

It’s so cool how you can just crank them out so fast. Even removing them from the molds was a breeze. Awesome process.

My wife, an occupation hygienist, commented that Adam should be using one of these set ups for everything, as he has a beard a normal mask won't seal correctly.

What I love about this channel is how it adds so much the overall enjoyment of videos seeing someone really seem be genuinely loving and having fun with what they are doing the way Adam does.

This is interesting. It's basically the exact same process for those spray on truck bed liners. They have a big air compression gun that heats and sprays the 2 parts, they mix in the air and cure very quickly on contact. I wouldn't be surprised if it was the exact same stuff.

What a wild technology! I am really hoping Adam got to bring some of his attempts home!

I love that there's always something new; a material, a process or a technique that advances the craft. Saving time and effort or improving quality, it must keep things interesting, even for those who have been working in the field for years.

Adam, I made the Winged-Hussar helmet on the left... That was cast from my master-armour for the film 1612. As a point of interest the helmet and associated armour took me six months to make, but FBFX spray-cast 42 complete half-armours in one weekend, whilst there was a private plane on standby waiting to go to the location. The master armour has a one-piece siege-weight steel skull, and weighs a hefty 3.2kg, whereas the Polyurethane helmets weigh abut the same as a packet of biscuits... Cookies for you on the other side of the pond. Keep up the great work and give my love to the mad-scientists as FBFX. 🇬🇧⚒🇺🇸

The sheer delight in Adam's eye makes this a fantastic little look into special effects. Thanks for bringing us along!

It's really cool how that dude is just so used to doing this super fast, it looks like he can't even slow down for a video. Nice!

Would love to see a one day build video of Adam finishing these helmets if he got to keep any of them.

It was hilarious & refreshing to see a grown man get so freaking excited about trying this process for the first time! Adam looked like he could hardly stand not being able to move faster! Haha. Awesome video because I never knew about this stuff!

oh, i love Adam in this situations so much. Especially this reality check moment when Laurence says he only "maybe" hire Adam. so fun

Thi is a testament to the quality of work from their mold makers. Fun video!

I've commented this sentiment on Adam's videos before but it bears repeating. His enthusiasm for the subject matter comes through so palpably that it makes this content compellingly watchable. And I have to believe he's encouraging people to become involved. I have so much admiration and affection for both the man and the craft.

I love how Adam knows enough to ask really well informed questions.

I always like to see a master in his craft learn a new technique. Never stop learining.

Loving these visits to various craftsman workshops. Great stuff.

I’ve been spraying a material very close to this and also this material for 15 years or so. Have made molds out of it many times for carbon fiber work. It usually gets sprayed into truck boxes and on industrial equipment.

These behind the scenes videos are wonderful! We want more!

Love it when Adam visits us here in the UK ❤

What a great technique. Very cool. Thank you for showcasing this.

adam enjoys this a lot and his joy is infectious

This is very cool, and you can see this is a man who lives with tight deadlines daily, and Adam's respect for that. A simple thought (from a simple mind), could you use compressed air to aid the demolding process somehow, or would that just risk breaking the casting? Maybe a plug that goes somewhere inconspicuous, remove plug, blast air, out she comes.

Incredible way to make something so fast yet look so real once finished !!!

I've done this job before. It's fun work but presents a lot of interesting challenges, you REALLY have to have a solid ability to conceptualize 3D spaces in your head to know where you need to go thicker or lighter in the mold. Having experience traditional sculpting, 3D modeling, and CAD/CAM comes in SUPER handy in this sort of spray work. I was really good at it but I was DEFINITELY much happier outside in the priming booth priming large rotocasted parts or final paint doing all the hand brushing after initial paint. Very monotonous stuff but much less involved than spray casting. I will say though having a forced air mask is a lot comfier than just sweating buckets in other parts of a hot workshop. Most recent shop I worked at had a whole department of guys who's enitre job was just cutting and sanding flashing, and patching little stuff with Bondo for parts like this. Now mind you, nothing we made was meant to be worn by people so we could get away with a hasty patch job on a lot of stuff.

i do this for a job and another cool thing you can do is spray a silicon mould with a cellulose paint before you spray the pu so it comes out painted.

Tested going from strength to strength these days, just knocking out brilliant videos!

Fun to see how you can still learn. Those masks with overpressure I used for the first time in 1995. They are great!

Lee Pace ,who played Thandrill from the Hobbit, would volunteer to work in the effects shop making armour. It really is addictive🛡️⚔️🗡️

im constantly envious of all the cool tools adam gets to use!

Laurence Moore, Adam's trainer here, is brilliant for just being straight forward with what went wrong for quick learning

I have tried this 3-4 years ago. I went to a polurea compagny with a silicon mold of a brestplate. I learned about this in your lich king armor video. Wyrmwick uses this techmique. I think they spray over real metal armor pieces. It's the finish that made me switch to something else. At the end of the day it is still a flexible rubber-like part that is painted. It looks good from a distance but it does not feel like the real thing at all when your have it on.

Really loving this content and the enthusiasm on display!

a blast of air in between the mold and cast, would help greatly

Worked at a boot company that made treads out of a very similar poly blend. We used injection molding instead of a spray, but the bubble voids are the giveaway. It was pretty awesome stuff, and it makes for a pretty comfy stool topper if you increase the foaming rate. Probably similar to the blend for stunt props that he mentioned at the end.

Really cool, we could see Adam was having a lot of fun making them. Did he get to take the fails home?. ( Future one day builds )

Adam found a new favorite 'dust/vapor' mask, we shall see if he gets one to use in his shop :) The audio was great even with it too.

That Exodus helmet is great! Would love to add that to my collection.

That is SUCH a cool process, I cant get over how fast they were to produce. Outside the master and mold making of course. I want one of those rigs, that's absolutely amazing.

Great to see you in the UK. Im sure we are giving you a warm welcome 👍

Wow!!! The Corinthian style Greek helmet displayed on the back is truly captivating, reminiscent of the authentic ones found in the Archaeological Museum of Ancient Olympia.

15:54 Looks like Adam is holding in all his giddy-ness, you can tell just how much this excites him. Its even making me excited too!

I had a couple thoughts: Can they do that with clear PU to make lenses? Could they do other colors? I'm thinking spraying white stormtrooper armor would outfit the whole 501st in short order. Could they use microballoons or glass fibers between layers to add volume? Would it be necessary? Would it just be itchy as hell? Soon, that spray booth is going to have a perfect polyurethane mold of the whole thing. They could just peel it out and have a whole new plastic spray booth. I'm curious what the "failure" rate is for these for experienced sprayers. I'd expect that a lot of these helmets would go to background guys in a big medieval battle, so how "perfect" do they need to be? Sometimes he says "it's too heavy," but how heavy is it, really? I'd think heavier would be better than lighter.

reminds me of spray on bed liners for trucks

Oh I'd love to try that! Such an amazing process and I'm shocked at how quick you can produce parts!

You can tell Laurence wanted to get shit done haha! Really cool process and seeing the results was fantastic.

It's like a low-volume, artisanal injection molding

That spray gun setup looks like a badass sci fi gun if ever I saw one ^^

An amazing process, wow

Wyrmric Armoury in the UK developed this technology 20+ years ago. They sell their armour to the general public.

Once you know the expansion and get the feel, its just feel. That's awesome. Adam needs a booth for this. He'd have a cosplay anytime he made a mold

PAPR’s are the best!! I wore one every shift for 15 months as an RN on the Covid Floor

Such a cool video and wonder if using tiny bit of air would get molds out quicker works with other stuff

I love how that room is like 50% fine, and 50% complete disaster area. :D

As someone who researches sprays of weird fluids, I love this.

17:42 Unplanned in-camera effect. The little people are here for their new houses.

The most exciting thing to me with Adam sharing videos of these processes, is that makers are going to figure out how to do this process at home with less expensive equipment. Give it a few years, and makers will be able to do this kind of process in their garage for their own projects.

Spray on bedliner is the same product. What a trip. Same type of setup.

I love that classic adam look where he looks over his glasses to look at something close

You needed two things to de-mold that cowboy hat, compressed air and blow chuck. If it works for handlebar grips, it will make the props pop out with less stress in the parts and molds.

I was watching this with my mouth open all the way. I am amazed at this :O

A quick jolt of compressed air between the mold and the part will probably get it out quickly and without tearing

Amazing process. I bet he brought all of them home.

Reminds me a pin-striping on cars. Really takes skill.

You're in the UK please organise a UK meet and greet I'd love to meet the guy that inspired me to become a maker!!

A cool process and Outbreak cosplay at the same time 😂

Those respirators are absolutely fantastic

Stunned this can make 60-70 things in a day! Imagine what can be done for other industries…..for lightweight shapes etc. Laurie. NZ.

I always thought those types of powered respirators were total overkill. Then I tried one on a job. Wow, never going back to the old way.

The thing is, the 'failures' of splits and thin cross sections? Take the mold back to the spray booth, spray up a patch, glue it in place and put on some false rivets and make it look like a battle damage repair. It will make the helmet look more realistic.

Next week on tested : Adam sets up his own spray set up and makes EVERYTHING lolol

Adam: "Yeah, I'll keep going..." yeah, dude. Adam just learned a new technique and material! He will work your whole shift for you now! Hahahaha

I would've enjoyed seeing how the helmets received their final finishing (metal appearance). Thanks for the interesting video.

Always wondered when demoulding things, could you use compressed air? like when buckets get stuck together or removing a handlebar grip without damaging it

"I'm dying to help you." Same energy as a kid going to a candy shop!

PLEASE tell me that there going to be a video on some of the DUNE headgear in the background. I have been drooling over that Sardaukar helmet and Duncan Idahos Pilot gear.

Very informative, and interesting. Thank you 👍

Adam: "This came out so great!" Master: "Lol, no."

who knew you could make hats out of bedliner???

Wow that’s astonishing! You could make a whole stormtrooper army in a week!

Wow, fantastic. I would think that unless one of these made here was for a Hero Shot they all could be used in crowded or mid-to-background shots. Painted up and dressed out any of these supposed flaws seem insignificant.

19:04 like a really weird robo cop haha

that guy undersold adam's efforts seemed pretty good ! nice work adam !

Great Adam sir

I would love to see how they paint these.

Fascinating! It seems like a far more flexible tool than vacuforming.

Would love to see a Stormtrooper outfit made entirely with this process.

Did you get to take all those helmets back to the cave so you can paint and weather them? I hope so.

Amazing! Now can we also see a video abotu how they apply the metal finish to the moulded helmets? I would have though they'd put metal powder or paint in the mould first and then have it stick in the material. But it's added after? How? Is it durable being added after?

*Question :* What happens to these props when the production is ended. Can they be melted down and used again or does the painting make it that they are just thrown out ?

Freaking dying of envyyyy!!! D: I want that for my little bussines! T_T