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Mold Making

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Zoe puppet plaster mold with registered armature.

Clay-up made from water based clay with 1/16" wire used as finger vents. 

Plaster was poured over clay-up and then mold was flipped after cure and prepped for second layer. Vaseline between layers to prevent the plaster sealing to itself, and keys added so mold holds together during injection process.

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Zoe one part head mold made out of GI 1000 silicone. Head was attached to a 1/8" wire with 1/16" wires attached to ears for venting. A corral was then made for the silicone and mold was used for urethane casts.

Elliot two-part head mold made from a clay-up and then molded out of GI 1000 silicone. Vents were carved out of the cured silicone so that the polyurethane foam would be able to vent.

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Clay-ups for the Big Sister and Little Sister face masks. These were then poured into two part molds using GI 1000 silicone. Delrin balls were embedded in the clay to allow the halves to key together. Mold used for urethane mask casts.

Clay-ups and flipped molds for Zoe's face mask mechanism. Separate molds were made for the mask and the core, both being made out of GI 1000 silicone. Delrin balls were used for keying. For the mask, since the part was so thin, strips of 1/16" wire were lined around the seam to allow for venting.

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Clay-up for Zoe's wig cap, made into a two-part mold from GI 1000 silicone. Delrin balls used for keying. Mold prepped and vented later for urethane casts.

Two part hand molds made out of GI 1000 silicone for Big Sisters hand. 1/16" wires used for venting and a cut syringe was used to allow a syringe to inject silicone. 3/16" wire attached to syringe to create an injection path.

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