Making a 2-Piece Silicone Mold to Cast Flexible Police Baton Prop
A recent New York stage production required outfitting a dozen actors with authentically
styled police batons. In addition to looking just like the real thing, some batons were
required to be stunt-ready props. Actors playing police were frequently thrown across
stage during brawls with other actors playing gang members. It was important that the
props be both flexible enough to be safe yet durable enough to resist the nightly abuse
on stage. Smooth-On's TASK® 13 semi-rigid resin made for the perfect
This step-by-step tutorial shows the process of making a two-piece block mold from a
police baton using Mold Max® 30 silicone rubber. It also shows how to cast a
reproduction using TASK 13 semi-rigid resin.
1 - Build a containment box to accommodate the original. Spread a 1/2'' bed of non-sulfur clay along the bottom of the box.
2 - Place the original into the box. Build clay around the original until one half of the piece is embedded.
3 - Using clay sculpting tools, cut registration keys into the clay bed.
4 - Add additional keys. Keys help the two-part mold stay properly aligned from cast to cast.
5 - Spray Ease Release® 200 over all surfaces where rubber will be poured.
6 - Weigh out Mold Max® 30 Part A. The appropriate mix ratio is 100 Parts A to 10 Parts B by weight.
7 - Weigh out Mold Max® 30 Part B.
8 - Dispense Part A into mixing bucket.
9 - Add Part B to mixing bucket.
10 - Thoroughly mix material until there are no color striations in the rubber.