Harrison Krix from Volpin Props was commissioned to create a replica from one of the members of the French techno group Daft Punk. This helmet was the fruit of 17 months of work. He chose Rebound 25 as the mold material to create a one piece glove mold and Plasti-Paste for his 3 part mother mold. To create the helmet itself, Smooth-Cast 300 was chosen to create a thin walled casting.
Additional information about the entire process can be viewed on his blog: Volpin Props Blog
Here is a YouTube video outlining the process:
The following images were provided by Harrison Krix.
1 - Final sculpt of Daft Punk Helmet, ready to be molded.
2 - A thin coat of Rebound 25 platinum silicone rubber is applied to pick up all the details of the original model.
3 - Undercuts are filled with thickened rubber and registration keys are applied.
4 - More registration keys and layers of rubber are applied until a 3/16'' thickness is achieved.
5 - The mold is now ready for the rigid support shell.
6 - The Plasti-Paste support shell is applied in multiple pieces for easier demold.
7 - Second part of support shell applied with an aluminum foil barrier between the shell pieces.
8 - The original model is demolded. Perfect detail is captured in the Rebound 25 mold.
9 - Detail of the inside of the mold.
10 - Smooth-Cast 300 is rotocasted into the mold and demolded.
11 - Multiple castings ready to be finished.
12 - The helmet is gold plated, outfitted with complex LEDS, visor, and other details.
13 - The helmet is gold plated, outfitted with complex LEDS, visor, and other details.