Cosplay Tutorial: Iron Man Helmet Silicone Mold

In this mold making how to video, we demonstrate how you can use Rebound 25 silicone rubber to make a mold of an Iron Man helmet. The original model is a 3D-printed helmet, which is coated in XTC-3D epoxy to make a smooth surface for capturing the mold.
#cosplay #ironman #helmet #silicone #mold
In Part 2, we go through the process of creating a lightweight epoxy support shell for this mold, then hand rotate an impact-resistant finished casting, ideal for cosplay or display: • Cosplay Tutorial: Iron...
Rebound 25 silicone: www.smooth-on....
XTC-3D epoxy: www.smooth-on....
Adult Supervision Required
Keep Out Of Reach Of Children
---
Make It Now! with Smooth-On
www.smooth-on....
/ smoothon
/ smoothon
/ smoothon
www.google.com...

[@Uberslug]

I wish this video existed in 2014 when I tried to do this!

[@BigCountryJC]

So what are the benefits of using this method versus the traditional matrix mold where the jacket is created first? Is it just that the Rebound is a brushable only silicone? The matrix mold method where you lay up the clay core, create the jacket, remove the clay and pour in the silicone seems like a faster process to me. I love your products btw and I am lucky to have a dealer close by.

[@smoothon]

A matrix mold is another great way to tackle a project like this, and a good idea for a future video. Usually there are several ways to approach a mold making project, and a brushed-on glove mold was the choice we made here. Some mold makers find making the brush mold first is a more straightforward technique versus a matrix mold that requires a little more preplanning.

[@danaoktavian9711]

hey bro thanks for your videos..!!very helpfull..i wanna quest..i dont have machine,for silicone before a molding..so,for what i wanna remove bubble in a silicone,without machine like in your videos..thanks

[@smoothon]

WE have some low viscosity silicones which do not need vacuum degassing such as the Mold Star series. www.smooth-on.com/product-line/mold-star/

[@lasarith2]

Hello, any chance you could do one for creating silicone prop prosthetics, (instead of the usual urethane prop from a silicone mold ) - how to (what smooth on products to uses) to create say a silicone mask/other, from clay model (a solid mold product ) and the end silicone mask (basically the reverse of the usual video 🙂 ( in other words what you did in this video but if you wear making the helmet out of silicone instead of urethane)

[@smoothon]

This is a great idea, thank you for watching!

[@jmgfx4161]

Good tutorial

[@smoothon]

Thank you and thanks for watching!

[@jmgfx4161]

Smooth-On you guys are great! I foind out about you guys at Savini's and have used your silicone and Smoothcast ever since.

[@samstrada2796]

Hi, Love your videos, I'm looking to get into mold-making for helmets on a bigger scale. I currently print 3D helmets but would like to speed up that process and mold in volume but not quite sure where to start with all the products. Do you have a full list of products required for each step of the process? I live in Australia.

[@smoothon]

Hi Sam, you can contact roweadvanced.com.au - they can assist you.

[@thevault3d4]

Hey Guys, can you do a video on making one for a muscle 3d printed piece for a muscle suit? It would be good to see how quadriceps etc would be done 👌

[@Adam_Dude]

If there's a crack in the helmet I want to make a mold of, is it possible to do this without the crack showing up in the helmets made with the mold?

[@smoothon]

You would need to repair the crack first using something like Free Form SCULPT epoxy,

[@colinhoffman7950]

Would this process also work on an iron man helmet made from 5mm thick craft foam?

[@PestVic]

I cant find rebound 25 in gallons anywhere???

[@oyamabuchanan305]

If I am doing 4 layers of rebound 25, is it okay to allow a complete cure between them or does it have to be partial cure between the first coats?

[@smoothon]

Complete cure is fine.

[@meerhawlery470]

How can I see the second part, please?

[@PANDANIKEFOOTBALL]

How many castings in pieces can be made from this mold? Until the shape starts to distort and deform? Thanks.

[@smoothon]

This depends on a lot of environmental factors. Check out this FAQ for more info - www.smooth-on.com/support/faq/183/

[@lancemarks9370]

Do you need to coat the original helmet with anything to get the silicone to release from it, or does it come off easily?

[@smoothon]

In this case no release was necessary.

[@lasarith2]

How much rebound 25 did the glove Mold take from the gallon units .

[@smoothon]

Approximately 2 quarts of material in total.

[@lasarith2]

Many thanks 🙂

[@UnexpectedAuto]

Hi, i bought rebound 25 for the purpose of brush-on full scale prop molds but have since changed direction to 1/6 scale headsculpts. I know mold max is the preferred silicone for it but can I use rebound 25 to make 2 part molds or isit too soft and flexible?

[@smoothon]

It can be used but the viscosity is quite high for a pour on mold.

[@SansAziza]

Which of your products would you recommend for making watch bands? (Flexible, but not stretchy; stiffens and typically cracks in cold weather.)

[@smoothon]

We would recommend looking into our Dragon Skin series of silicones: www.smooth-on.com/product-line/dragon-skin/

[@angelraymundolozadagallego3973]

Which brand of clay did you use? May you recommend a list of compatible clay brands?

[@smoothon]

Non sulfur clay such as Chavant NSP works well

[@jeanetedreyer-sculpturedolls]

Amazing

[@smoothon]

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

[@skyrider4789]

Is Thi-vex required to make a successful brush-on mold with Rebound 25? I have some on order, but trying to make progress before it arrives.

[@smoothon]

Thi-Vex is optional. You will end up needing more thin coats. I do however recommend Thi-Vex when filling deep recesses.

[@skyrider4789]

@@smoothon thank you. I will wait.

[@smoothon]

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

[@UnexpectedAuto]

will the mold last longer if a seam is cut at the back for easier demolding compared to tugging and folding a glove mold? also how do you estimate the volume of silicone used for each layer?

[@smoothon]

In some cases, a seam can create a longer lasting mold due to reduced stress on demold. You can use a surface area calculator to estimate how much material is needed. Check out our brush on mold estimator here - www.smooth-on.com/support/calculators/#brush-mold

[@abes9981]

Hi! I'm all new to this like super new... I'm 21 years old but I want to learn how to mold and make props etc. I wanted to make a mandalorian helmet. I have a question, so I would need to buy such helmet and THEN I can mold to make my own and paint it etc. So my question is I would need to buy the helemy from somewhere in order to make multiple props?

[@smoothon]

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

[@evoFTMFW]

No. You need to make your own helmet first (hand sculpt, 3d print, pepakura, etc) and then cast it. Recasting someone elses work is a huge no no and will get you booted out of every single prop maker community.

[@jonnyhernandez6899]

I have a helmet i have made out of eva foam, but would like to redo it and make it the slush casting way. is it possible to make a silicone mold out of my already finished eva helmet?

[@smoothon]

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

[@ReneeNme]

I just purchased a life size 1989 Michael Keaton as Batman rotocast bust and the person I bought it from cast it rather thin and I'd like to thicken the face section before beginning finish work on it. Question: If I used Smooth-Cast 65D on the already finished product, is there a chance that the 65D might deform the bust due to the heat it creates when curing ? If so, can you suggest another alternative ?? This was the final cast of this bust and the last thing I want to do is ruin it.

[@smoothon]

Do you know what the bust is made out of? In a thin section, 65D may not heat up enough to cause distortion, but we would need to know the material the bust was made from.

[@lasarith2]

ReneeNme ? 🤷🏼‍♂️ a Possible idea is to make Paper mache, then somehow attaché it to the inside to strengthen the mask for when you are wearing it (I’d say get tin foil and duct tape to make a temporary mold of the inside part of the mask that’s the thinnest so you can make the copy paper mache mold for the inside, I’m just hopping the mask Isn’t too thin for this to maybe work 🤷🏼‍♂️ the last thing I want is the mask to crack when you’re trying it, or if you decide to try.

[@lasarith2]

ReneeNme here’s a video I’ve found that’s somewhat what I’m thinking of kzbin.info/www/bejne/oqiVmpltqqx1r5Y

[@ReneeNme]

+ Smooth-On I was able to contact the seller and he informed me that the product used was Quickcast by Silpak. He also said that Smooth-Cast 65D would be compatible. Would that be correct ? + Iasarith2 Thanks for the tips. The piece really isn't made for wearing, it's for display. If you watch the video titled 89 Keaton Batman Life Size Bust by Howard Senft Studios mine is a B recast of it.

[@lasarith2]

ReneeNme okay 🙂 you’re welcome . Ahh I see what you mean about the head cast .

[@pwiest2545]

Hello there. I have a question. Will this method also work on a First Order Stormtrooper helmet? As it has a bit more details on it and I am worried that it might not work as it should. Cheers and have a nice day ^^

[@smoothon]

Rebound 25 will pick up fingerprint details when applied correctly.

[@pwiest2545]

@@smoothon Thanks you for the reply! I already found the supplier from the site that you recommended. Cheers!

[@michaeldiaz6570]

can drying time vary if you are a cold or hot environment?

[@smoothon]

Yes, a warm environment will accelerate the cure. Materials should not be used at temperatures below 60F.

[@ragztv4927]

What material is that? The oramge and white

[@smoothon]

That is Rebound 25 silicone. www.smooth-on.com/products/rebound-25

[@ragztv4927]

Can i use other brand of silicone rubber

[@mattnudds1258]

Is the rebound 25 the same material as the oomoo 25 ???

[@smoothon]

Rebound 25 is a brushable platinum cure silicone with extreme tear strength. OOMOO 25 is a pourable tin cure silicone with lower tear strength.

[@adammurnane2400]

Can you put this on wed clay to mold.

[@smoothon]

Yes you can. You may want to apply a thin layer of clear acrylic spray first.

[@adrianghdez_]

how much amount of rebound 25 was used?

[@smoothon]

About 2 trial units.

[@adrianghdez_]

@@smoothon 1.8 kg approximately ?

[@smoothon]

Yes

[@engineerofalltrades]

You mean sculptit clay?

[@smoothon]

Sculptex is a brand sold bywww.reynoldsam.comm

[@rodiantorres5656]

hi there! great vid! if i'm molding a one-off piece, can i use smooth-on's EZ~Mix or Econ® Series instead? would that be a cheaper yet effective alternative to using platinum silicone?

[@smoothon]

Rodian, that is a good idea.

[@seekertosecrets]

To the guy that was wearing the War Machine Helmet... You goof ball!

[@ffili92]

I can't even make the clay bed 😩

[@beckybraun7996]

I want to do this on a metal statue, I need a professionals assistance. I live near Pittsburgh.. Any advice?

[@smoothon]

Thanks for watching Becky Braun. We do not provide moldmaking services, but we do have a list of moldmakers on our website: www.smooth-on.com/moldmaker/

[@seekertosecrets]

Fiberglass...Oh boy. First time I used it, it was not a happy time.

[@AlienArteStoreMX]

I agree, I hate working with regular fiberglass, it's an itchy mess, I hope fiberglass cloth is different

[@murrayharrisonharrison2022]

How to make a Batman mask.

[@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 by following this link - www.smooth-on.com/support/ticket/add/agree/ .

[@madzferg8139]

How much silicone and how much resin for the actual helmet did you use

[@smoothon]

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