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How to Make Prop Movie or Fantasy Swords out of Flexible Foam

Production companies regularly contact Smooth-On looking for an easy way to reproduce multiple prop weapons for stage and screen. These props are often used by extras in large battle scenes and must be easy to carry and safe to use. Smooth-On's FlexFoam-iT!® expanding flexible foams make an economical and safe choice.

This tutorial shows how to cast a FlexFoam-iT! 25 stunt prop sword into a Mold Max® 30 silicone mold. FlexFoam-iT! 25 develops a tough outer skin making it ideal for the finished piece. Smooth-On's Cast Magic® powders are a fast and easy way to add color and depth to any casting. The completed prop is lightweight, flexible and safe.
 Gather materials.

1 - Gather materials.
 Brush Cast Magic® Silver Bullet powder onto mold surface.

2 - Brush Cast Magic® Silver Bullet powder onto mold surface.
 Carefully close the mold.

3 - Carefully close the mold.
 Secure mold with adjustable straps.

4 - Secure mold with adjustable straps.
 Turn mold on end with pour spout facing up.

5 - Turn mold on end with pour spout facing up.
 Insert a wooden dowel into mold to give final piece added strength.

6 - Insert a wooden dowel into mold to give final piece added strength.
 Measure Part A.

7 - Measure Part A.
 Measure Part B.

8 - Measure Part B.
 FlexFoam-iT!® 25 is measured 1A:2B by weight.

9 - FlexFoam-iT!® 25 is measured 1A:2B by weight.
 Add a few drops of SO-Strong® Black to Part B.

10 - Add a few drops of SO-Strong® Black to Part B.
 Thoroughly mix pigment into Part B.

11 - Thoroughly mix pigment into Part B.
 Combine Part A with Part B.

12 - Combine Part A with Part B.
 Thoroughly mix Parts A and B together, being sure to scrape sides and bottom of container.

13 - Thoroughly mix Parts A and B together, being sure to scrape sides and bottom of container.
 Immediately after mixing, pour material into the mold.

14 - Immediately after mixing, pour material into the mold.
 Once fully cured, demold sword.  Cast Magic® powders will bond to the foam as it cures.

15 - Once fully cured, demold sword. Cast Magic® powders will bond to the foam as it cures.
 Finished piece is lightweight, durable and safe!

16 - Finished piece is lightweight, durable and safe!

                   
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