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Plaster
*Responsible for all mold-fabrication
Frog Body Mold
The Frog is cast in a three-part Plaster mold, the two larger halves hugging the body and the smaller third piece being used at the base of the mold to help register the large feet.
1/3: First Half
The Sculpt is first sprayed in Krylon Crystal Clear, and then water based clay is used to build up the clay up around the sculpt. This was a rather large character, so the clay up took some time. The mold is designed with the legs spread out as much as reasonable to allow the puppet to crunch its legs and stretch them out in a natural and frog-like way. The overall shape of the mold is done to conserve as much material as possible, so sections of the sides of the mold were cut out to follow the silhouette of the frog.
Plastic cast sphere keys and were added to ensure both halves locked securely together. And foam core walls were placed around the perimeter of the mold. Plaster was poured into the foam core corral. A small brush was used to prevent bubbles from hugging the sculpt. Burlap was added into the bottom layers once the sculpt was fully covered, to help improve structural integrity.
2/3: Foot Registration Block
Due to the frogs wide webbed feet, a separate foot block was necessary to ensure a clean model that could easily be removed from the mold, without distressing the puppet or affecting the cast. This also helped to make registration far more convenient.
A mold release was applied and Plaster was once again poured into the corral. A small brush was used to prevent bubbles from hugging the sculpt. Burlap was added into the bottom layers once the sculpt was fully covered, to help improve structural.
3/3: Final Half
Water-based clay was once again used to shape a raised impression on top of the fist half that will result in trenches on the second half once is it poured and the clay is removed. These give a place for the excess foam to go during casting.
Foam core walls were placed around the perimeter of the mold, a mold release was applied to the exposed plaster from the first half. Plaster was poured into the foam core corral. A small brush was used to prevent bubbles from hugging the sculpt. Burlap was added into the bottom layers once the sculpt was fully covered, to help improve structural integrity.
Final Body Mold
Anchor 1
Luci Body Mold
Anchor 2
Luci's body mold is comprised of two plaster halves. The first is poured over a water-based clay build-up around the sculpt, with registration keys included to help both halves fit together. The second is poured over the first half, with trenches sculpted on top so that, when the puppet is cast in foam, the excess foam has a place to go and doesn't force the mold apart.
Final Body Mold
Beginning Clay up
Finished clay up with foam core corral
First half poured
Second clay up finished with foam core corral
Second half poured
Roxy Body Mold
Roxy's body mold is comprised of two plaster halves. The first is poured over a water-based clay build-up around the sculpt, with registration keys included to help both halves fit together. The second is poured over the first half. The mold includes finger channels that allow air to pull the silicone up through the bottom of the mold, and ensures all fingers are filled properly during the injection process.
Final Body Mold
Anchor 3
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