Trying to get into traditional sculpting or prosthetics for your costumes? You might be asking, “how do I make my own silicone molds for cosplay?” We’re going to go over the supplies, materials and different techniques so you can cast molds like a pro.
What Do I Need to Make My Own Silicone Molds
- Master object (clays, 3D prints, etc.)
- Mold box or materials to make one
- Mold release
- Tin or Platinum cure silicone (can be bought as a kit)
- Safety gear (gloves, goggles and masks)
- Registration keys as needed
- Mixing cups and sticks
- Mother Mold such as plaster (brush-on mold making)
- Brushes (brush-on mold making)
- Degasser (optional)
How to Make a Silicone Mold
There is a few methods to make a silicone mold. There’s the pouring method and brush-on.
Pouring Method
- Step 1. Prepare a master object – Either via 3D printing, sculpting, etc., you need to get your master object. Make sure it’s clean and if porous, sprayed with sealant.
- Step 2. Prep a mold box – Create your mold box and ensure it’s big enough for at least 1/2″ of space between the object and the walls. You can then place your object in the box and secure it in place with hot glue. Then apply your mold release. This is when you would also add registration keys as needed.
- Step 3. Mix and prep your silicone – Measure and mix your silicone by following your specific kit’s instructions. Thoroughly mix and scrape the edges of the cup you mix it in. You can degas it to prevent air bubbles or use the “bombs away” method when pouring.
- Step 4. Pour – Pour your silicone into the mold box in a slow, thin stream into the lowest point of the box. Pouring from high up can help prevent air bubbles. Allow the silicone to rise and cover the object as you pour.
- Step 5. Cure & de-mold – Let the silicone cure fully by following the kit’s specific instructions. Then remove the mold box and gently peel the silicone away from the original object.
Brush-On Method
- Step 1. Prepare a master object – Either via 3D printing, sculpting, etc., you need to get your master object. Make sure it’s clean and if porous, sprayed with sealant. Then apply your mold release.
- Step 2. Mix and prep your silicone – Measure and mix your silicone by following your specific kit’s instructions.
- Step 3. Brush on the silicone – Apply a thin base layer to the item to capture the fine details. Then add your thickening agent to the silicone mix and begin adding thickened layers. Leave time for each layer to become tacky before adding another.
- Step 4. Make a “mother mold” – Reinforce the mold with a mother mold such as plaster bandages.
- Step 5. Cure & de-mold – Let both molds cure fully by following the product’s specific instructions. Then remove the mother mold and gently peel off the silicone mold.
Can You Use a 3D Printer to Make Molds
You can 3D print a master object from a 3D printer to then make a silicone mold from. It’s a popular method to choose over sculpting for low-volume production, rapid prototyping and custom casting. Resin prints are usually favored though since they have high-precision and get smoother surfaces over filament prints that will require surface prep.
How to Make a Silicone Mold Out of a 3D Print
To make a silicone mold from a 3D print, you use the standard techniques for making a silicone mold but the print will be your master object. There is some prep work to do for your 3D print before you can just use it as the master object.
- Step 1. Surface prep – Resin prints need to cure and filament prints need surface prep. Sand your 3D print and finish with a round of wet sanding for a super-smooth finish.
- Step 2. Clean the print – Clean off any dust from sanding to ensure it’s cleaned and fully dried for casting.
- Step 3. Seal the object – Filament prints are porous. So apply a coating to fill the layer lines so it’s smooth before casting.
What Material Can I Use in a Silicone Mold
Silicone molds can be used for a variety of materials that cosplayers often work with, such as:
- Casting resin/liquid plastic/polyurethane resin
- Epoxy UV resin
- Foam clay
- Prosthetics (liquid latex or silicone when the mold is tin-cure)
- Plaster
- Hot glue
- Polymer clay
How Much Does it Cost to Make a Custom Silicone Mold
The price will vary depending on the size of the object you are casting, as it’ll require more silicone for larger objects. Brush-on molds can often cost more since you also need to create a mother mold. The details can also impact the cost.
- Small/simple molds – $40 – $200
- Basic/medium sized molds – $500 – $2,000
- Large/detailed molds – $2,000 – $5,000
- Extra large/advanced/multi-cavity molds – $5,000 – $20,000+
- Custom molds for cosplay – $500 – $5,000+
Can You Make a Mold Out of Hot Glue
An alternative for silicone molds would be making them out of hot glue. You simply cover the master in hot glue and as it cools you should have a mold as the result. They aren’t always as high of quality or durability though and will require a lot more hot glue than you may realize. This can be a better, more affordable option for smaller pieces such as gems.
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