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Urethane
*Responsible for all mold-fabrication
Gregory Body Mold
Gregory is cast in a three-part Urethane mold, the two larger halves hugging the body and the smaller third piece being used around the neck wire to help register the armature.
1/3: Neck Registration Key
The key was first sculpted in Chavant Clay before foamcore walls were placed around it.
GI 1000 molding silicone was activated and then poured into the foamcore corral to create an impression of the sculpt.
A 5/36 brass tube is registered into the mold, and is used to attach a silicone lid.
Urethane is poured around the brass tube and into the mold before a silicone lid is placed on top to ensure a flat bottom to the hero key.
After the key is cast, the excess brass tube is cut off with a brass tube cutter and the edges are sanded to avoid scratching the wire.
2/3: First Half
The surface area of each half of the mold was calculated to estimate the amount of Urethane necessary to pour the entire mold with the least amount of excess possible.
3/3: Second Half
Sculptex Soft clay was used to create the clay up around the hero body sculpt, keys and a foot block was added to ensure both halves locked securely together.
A mold release was applied and Urethane was poured over the clay up and into a foamcore corral (And newly added neck key), while compressed air was gently sprayed into the Urethane to remove any bubbles that formed around the sculpt.
The foamcore walls and Sculptex clay were removed carefully to avoid damaging the sculpt.
Final Body Mold
Sculptex 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 sculptex is removed. These give a place for the excess silicone to go during a smash cast.
Mold release was once again applied and Urethane was again poured over the clay up and into a foamcore corral, with compressed air once again lightly sprayed into the Urethane to remove bubbles.
When installing the armature, first the neck registration key is placed over the neck wire which helps make the registration of the armature much quicker and more secure. Then the armature and key are placed into the mold, the key will click into the mold and the bolts within the tie downs are placed into the foot block. Finally, the second half is placed on top, closing the mold.
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