Cosplay Tutorial: Iron Man Helmet Casting

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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[@paisley436]

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

[@smoothon]

Thank you for watching!

[@ericprint3576]

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]

Great to hear!

[@vincentb2175]

Wow! Great work, very impressive.

[@JOEGGGJOE]

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

[@smoothon]

Thanks for watching!

[@aflah4863]

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

[@aflah4863]

@@smoothon how to buy this mold

[@Viridisdaemonis]

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

[@smoothon]

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

[@bryansiepert9222]

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]

Excellent point!

[@rodiantorres5656]

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]

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

[@candidate17]

This! I'm glad someone asked

[@riyawandwinugroho1277]

Thank you for this amazing tutorial..

[@smoothon]

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

[@dr-onestuffido]

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 :)

[@boujme3457]

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

[@volcheq2041]

Thank you for the content!

[@smoothon]

Thanks for watching! 😃

[@ReneeNme]

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]

Sounds cool! Thanks for watching!

[@ReneeNme]

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]

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]

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

[@ReneeNme]

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.

[@JoseLuis-tn5qi]

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

[@PANDANIKEFOOTBALL]

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

[@smoothon]

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

[@jansieber1503]

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

[@mattnudds1258]

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

[@janzumkley6897]

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

[@smoothon]

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

[@michaeladams5340]

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

[@vedasvirtue5571]

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]

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

[@Cezararteprojetos]

Show parabéns mais um inscrito

[@smoothon]

Thanks for watching! 😃

[@littlewiihacker]

What grit sandpaper did you use?

[@KRGraphicsCG]

I definitely want to do this with my face mask

[@akshaytilawane9068]

nice

[@jerrybatacas]

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

[@smoothon]

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

[@dreroelandt2246]

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]

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

[@ricosuave4275]

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]

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

[@drsmiff777]

how much 57D per cup are you using?

[@chevelle99xify]

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 !!!!!!

[@perigosu8449]

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]

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.

[@mtkuennen84]

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

[@smoothon]

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

[@seekertosecrets]

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]

You should wear gloves when handling fiberglass.

[@j.danaclark89]

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

[@smoothon]

Thank you for watching!

[@Deathbysnusnu125]

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

[@smoothon]

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

[@FreddyFX]

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]

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

[@hannahblock8984]

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]

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

[@lawsongangster]

mark 1 iron man helmet

[@nizam8979]

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

[@smoothon]

Definitely

[@mattnudds1258]

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

[@smoothon]

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

[@stickman787]

IM getting some of that 57d....

[@smoothon]

It's amazingly strong resin!

[@herv4851]

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]

A wash with mineral spirits can help.

[@manuelcalle6506]

Can you also fill the mold with rigid polyurethane resin?

[@smoothon]

Yes you could.

[@rdgk1se3019]

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

[@smoothon]

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

[@samscreativeally1528]

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]

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

[@aaronli1540]

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]

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!

[@seekertosecrets]

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]

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

[@seekertosecrets]

Okay, I just sent a tech ticket.

[@skyrider4789]

Can carbon fiber be used instated of fiber glass cloth?

[@smoothon]

Yes it could.

[@ragztv4927]

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

[@smoothon]

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

[@kenyonhope879]

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

[@smoothon]

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

[@user-kl9tw7ti5e]

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]

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.

[@UnexpectedAuto]

would like to learn how to do a matrix mold

[@smoothon]

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

[@johnmoore2344]

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

[@smoothon]

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/ .

[@seekertosecrets]

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

[@smoothon]

Yes, it can be sanded, cut and drilled

[@snakeeyes037]

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

[@smoothon]

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

[@KevinReillySV]

Does a trial size work for one helmet?

[@smoothon]

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

[@andreprieto8916]

Does this resin also work with carbon fiber parts?

[@smoothon]

Yes, EpoxAmite resin will work with carbon fiber.

[@jansieber1503]

Any Idea how much Clay would be needed?

[@lasarith2]

Probably about 6-7 of the sculptex

[@p2studio807]

how buy Smooth-Cast 57D in thailand?

[@smoothon]

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

[@xxxxzorroxxxx]

Can I use this to make rubber tires 57D

[@smoothon]

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

[@PizzaOignonGaming]

i buy !

[@baljazz]

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

[@smoothon]

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!

[@orlandofontanez1687]

Can you make a batman Cowl mask with the same kit

[@smoothon]

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

[@KurtisJoseph]

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]

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]

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

[@AbdullahKhan-yj5lz]

But how could I make the mold without an actual helmet

[@TheRobmcknz]

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.

[@Meyvn08]

Do Jason Todd Red hood helmet

[@janzumkley6897]

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]

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

[@jimmahbee]

Can you do the body armor?

[@smoothon]

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

[@PrayerIsMyHabit]

How much would a process like this cost to replicate

[@smoothon]

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

[@mineurbiz]

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]

Thanks, this is a great idea!

[@mineurbiz]

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

[@flexiwing4450]

Hi great tutorial i need little suggestion plz reply

[@smoothon]

What can we help with?

[@flexiwing4450]

@@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]

@@smoothon fiber mesh used for water proofing

[@smoothon]

You would have to test this for performance independently.

[@flexiwing4450]

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

[@mykalimba]

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

[@smoothon]

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

[@didiermolina3909]

Can you sand this material?

[@smoothon]

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

[@driversteve9345]

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

[@smoothon]

That would be great! Thanks for watching!

[@h.radican]

HQ!

[@smoothon]

Thank you for watching!

[@abdonafea4911]

HOW CAN HAVE THIS MATRRAIL IN EGYPT

[@smoothon]

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

[@amirulmukmin4965]

try mold and cast a sword

[@smoothon]

Good idea, thank you for watching!