Cool Mold Tutorial | Roto-Casting a Skull in Resin and Foam

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In this helpful video, we show the process of molding and casting a highly detailed skull using two different casting materials in the same mold. This video illustrates making a brushed on silicone "jacket" mold with a rigid support shell. This mold is useful for Rotocasting a variety of casting polyurethanes as well as being able to produce parts using expanding polyurethane foam. We hope that some of these tips and tricks help you on your next project. If you are new to mold making, we have many intro molding and casting videos that go through much more detail and simpler parts so be sure to check out our RU-vid channel!
For more info on BJB materials, visit www.bjbenterprises.com
Materials used in this video:
TC-5024 25 SHORE A TIN SILICONE
bjbmaterials.com/tc-5024-a-b/
BR-75D BRUSHABLE 75 SHORE D POLYURETHANE
bjbmaterials.com/br-75d-brush...
TC-874 A/B 70 SHORE D EASILY PIGMENTABLE URETHANE CASTING SYSTEM
bjbmaterials.com/tc-874-a-b/
PIGMENT COLORS
bjbmaterials.com/pigments/ure...
PLASTALINA MODELING CLAY
bjbmaterials.com/accessories/...
E302 ROCKET RELEASE - PAINTABLE (NON-SILICONE BASED)
bjbmaterials.com/e302-rocket-...
MOLD VENTS, SPRUES, REGISTRATION KEYS, AND MORE
bjbmaterials.com/accessories/...
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Опубликовано:

1 авг 2024

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Комментарии : 33

@StasonKalbason 13 дней назад

Молодцом!

@Chrixelpixel 4 года назад

Great job!

@orderdouse 4 года назад

Спасибо за этот ролик. Информативно и подробно.

@lefkytheshin Год назад

Ha. Oh, jeez, where did I leave my giant roto-cast machine?

@captainjerk 4 года назад

I will use this method soon.

@bjbenterprises 4 года назад

Great! Let us know how it goes.

@KRGraphicsCG 2 года назад

This is killer... And it looks like I can use TC-874 for something that I'm working on, and it looks good for roto casting helmets

@alastairohara7265 4 года назад

lovey

@charleshoppe4295 4 года назад

I have a resin skull with viking carvings. I want to add clear epoxy with blue dye into the eyes, nose and cheek hollows..is the possible with it messing it up?

@bjbenterprises 4 года назад

Without seeing the piece it's hard to give advice. Anything is possible and it would depend on many factors like the shape and features of the skull. You can certainly tint and epoxy and get it to bond to a resin cast piece but will the areas you plan to add resin to keep the epoxy from running away from the area. You may need to thicken it to help it stay in place or it may indeed just stay there.

@benjaminroney6054 2 года назад

Using this technique, how long does your silicone mold hold up/how many accurate castings can one expect? And which material/technique would you recommend for durability on a display piece? I've been approached to do trophies approximately this size, just trying to figure out which way to go for repeatability/speed/low prep before finish time... 🤔

@bjbenterprises 2 года назад

For a brushed silicone jacket mold like this, we would expect somewhere around 15-20 parts as a conservative estimate. The main issue is the relief cut on the backside of this particular mold. If you made this into a 2-part silicone mold, it should last even longer because you aren't stressing the silicone as much. For materials, we have several options. I'd say something this size, you could do a "slush cast" by rolling the material by hand in a couple layers using our TC-808 rigid urethane. If you are painting the trophies your options are much more open. If you want the parts to pop out done with a particular color, then we need to have a conversation. Feel free to reach out to our tech team to discuss: info@bjbenterprises.com or 714-734-8450

@benjaminroney6054 2 года назад

@@bjbenterprises thanks so much for all of the info! Yes, they would be finish painted, but casting them in a uniform base color would be great. Regardless of the medium, I had assumed a 2 piece mold until I saw this video, which is why I wondered. I will definitely reach out to that email and "ask the experts" asap, so thanks for sharing that!

@alpaykasal2902 3 года назад

Hi, i am researching methods for recreating a few hundred cruise ships which will have some fine details. Would you say that backpressured foam or rotocast resin will have a better surface quality? I have more experience with polyester resin but foam seems like it'll be much easier to crank out since i haven't built rotocasters before. Thanks!

@bjbenterprises 3 года назад

Foam is MUCH more difficult to get consistent skin quality compared to a normal casting resin. How big is the model (length and width)? If the part isn't too large, you could do a combination of both to make strong lightweight parts. Use a quick curing rigid material as the rotocast skin surface, and then back it up with a 2-part rigid foam for ultimate strength. Would be much faster than fiberglass and resin molded parts.

@alpaykasal2902 3 года назад

@@bjbenterprises thanks for the reply! You're awesome. it's a cruise ship of about 18" long. i don't have the 3d model yet (which i will cnc or 3d resin print) still awaiting that. As much as I'd LOVE the experience of rototcasting, i'll have to build the rotocasting machines. Not a terrible experience to gain, but a big extra step. I was hoping 2part foam with back pressure would do the trick but i suppose not , if you think the surface will be inconsistent. I might try to manually roto/slush with polyester for a well defined shell (like you suggest), by just rotating it in my hand with a resin that sets quickly... then do foam into it, like you were saying above. great thinking. Definitely a worthwhile test. Thanks so much for the info!

@bjbenterprises 3 года назад

@@alpaykasal2902 ok, that's smaller than I assumed. Hand rotocasting (aka slush casting) is definitely an option. You might want to consider a fast-cast rigid polyurethane for the skin due to it's compatibility (bonds extremely well) with 2-part PU expanding foam and lack of styrene smell. A good example of that is here in this video: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-S4yfbn4wdmI.html

@alpaykasal2902 3 года назад

@@bjbenterprises You're great!!! Thank you for the recco, and that black color is so pretty in that video too! Slush casting it is. I really appreciate the guidance. I will probably do a 'behind the scenes' video of this project and I'll be sure thank you and point people your way.

@manueltallini1660 2 года назад

Your website doesn’t work, I want to buy all this products from this video

@bjbenterprises 2 года назад

the website had maintenance going on at the time.

@resinart2098 3 года назад

This was intense! Is there an easy way!?🤦🏽‍♀️🙆🏽‍♀️

@bjbenterprises 3 года назад

There will always be trade-offs to find an easier way. You could make a solid, 2-piece silicone mold but it will be extremely heavy and expensive. You can do a traditional "matrix mold" but that will require more prep time and use roughly the same amount of material. Knowing how many pieces you want to make out of a mold is also how you help determine what mold making strategy to use. If you are only making 1 or 2 pieces, you may be fine to made a mold in a quick and crude manner. If you plan to make dozens of parts, then you will want to spend a little extra time up front to make a mold that works "for you" and not "against you." By that, we mean making a mold that doesn't create a lot of extra clean up work after demold.

@scottdixon2697 3 года назад

How much would it cost for all the materials you used? I can imagine that medical grade casting wasn't cheap.

@bjbenterprises 3 года назад

For a mold making project of this scale you are looking at around $300-400 if you are completely starting from scratch. You will need silicone, brushes, mixing cups, mold release, rigid urethane shell material, and then the casting material you want to make the skulls from. Making a mold is an investment assuming you need many copies so it's not always a cheap endeavor. By the way, what do you mean by medical grade? These are not medical grade materials used in the tutorial.

@scottdixon2697 3 года назад

@@bjbenterprises oh I apologize. I've been watching so many of these videos that I guess i put that on the wrong comment. He used medical grade casting, like a cast for a broken bone on the outside. It didn't look quite like yalls. But I might have hit the back button too many times, im kind of a dumbass sometimes, but hey who isn't. Anyways thanx for the reply and the info.

@Micheeore69 Год назад

Can the rotocasting be done by hand? 😮

@bjbenterprises Год назад

Yes, you can do hand roto-casting. We often call this slush or slosh casting. You end up with less of an even wall thickness, but it is an easy way to pop out a handful of parts.

@Micheeore69 Год назад

@@bjbenterprises I’m looking to cast out a Star Wars lekku head piece for Ahsoka that I’ve seen done. Just not sure where to start and what products to use, such as material, the foam fill, silicone vs latex, etc. any advice should be helpful. Thank you.

@bjbenterprises Год назад

@@Micheeore69 you might be referring to Wretched Hive Ahsoka. Those use BJB flex foam filled pieces with a latex skin. How to make one is quite a process. Your best bet for that would be to join one of the movie prop groups and see how others have done a part like that. From what we are told, there was a lot of R&D done to create those pieces.

@Micheeore69 Год назад

@@bjbenterprises thank you for your help!