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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 choice.

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.
 Build a containment box to accommodate the original. Spread a 1/2'' bed of non-sulfur clay along the bottom of the box.

1 - Build a containment box to accommodate the original. Spread a 1/2'' bed of non-sulfur clay along the bottom of the box.
 Place the original into the box. Build clay around the original until one half of the piece is embedded.

2 - Place the original into the box. Build clay around the original until one half of the piece is embedded.
 Using clay sculpting tools, cut registration keys into the clay bed.

3 - Using clay sculpting tools, cut registration keys into the clay bed.
 Add additional keys.  Keys help the two-part mold stay properly aligned from cast to cast.

4 - Add additional keys. Keys help the two-part mold stay properly aligned from cast to cast.
 Spray Ease Release® 200 over all surfaces where rubber will be poured.

5 - Spray Ease Release® 200 over all surfaces where rubber will be poured.
 Weigh out Mold Max® 30 Part A.  The appropriate mix ratio is 100 Parts A to 10 Parts B by weight.

6 - Weigh out Mold Max® 30 Part A. The appropriate mix ratio is 100 Parts A to 10 Parts B by weight.
 Weigh out Mold Max® 30 Part B.

7 - Weigh out Mold Max® 30 Part B.
 Dispense Part A into mixing bucket.

8 - Dispense Part A into mixing bucket.
 Add Part B to mixing bucket.

9 - Add Part B to mixing bucket.
 Thoroughly mix material until there are no color striations in the rubber.

10 - Thoroughly mix material until there are no color striations in the rubber.
 Vacuum degassing minimizes bubble entrapment in thick silicone rubber.

11 - Vacuum degassing minimizes bubble entrapment in thick silicone rubber.
 Pour Mold Max® 30 in a long, thin stream over the original.

12 - Pour Mold Max® 30 in a long, thin stream over the original.
 Continue pouring until the highest point of original is covered with at least 1/2'' of silicone.

13 - Continue pouring until the highest point of original is covered with at least 1/2'' of silicone.
 Once the rubber has fully cured, remove the clay and place the block back in the box.  Do not remove the original!

14 - Once the rubber has fully cured, remove the clay and place the block back in the box. Do not remove the original!
 Spray Ease Release® 200 over the entire surface.  This will allow the silicone to separate from itself.

15 - Spray Ease Release® 200 over the entire surface. This will allow the silicone to separate from itself.
 Mix and pour a new batch of rubber. The highest point of original should be covered with at least 1/2'' of silicone.

16 - Mix and pour a new batch of rubber. The highest point of original should be covered with at least 1/2'' of silicone.
 Once the rubber has fully cured, remove the original model from the mold.

17 - Once the rubber has fully cured, remove the original model from the mold.
 Use adjustable straps to clamp the mold together. Wooden boards prevent the straps from deforming the rubber.

18 - Use adjustable straps to clamp the mold together. Wooden boards prevent the straps from deforming the rubber.
 TASK® 13 is a semi rigid urethane resin that is mixed 100 Parts A to 120 Parts B.

19 - TASK® 13 is a semi rigid urethane resin that is mixed 100 Parts A to 120 Parts B.
 Weigh out Part A.

20 - Weigh out Part A.
 Weigh out Part B.

21 - Weigh out Part B.
 Combine Parts A and B and mix thoroughly.

22 - Combine Parts A and B and mix thoroughly.
 Pour TASK® 13 into the Mold Max 30 mold.

23 - Pour TASK® 13 into the Mold Max 30 mold.
 Once the resin has fully cured the mold can be peeled away from the reproduction.

24 - Once the resin has fully cured the mold can be peeled away from the reproduction.
 Finished casting is flexible and much safer for stage than the solid wood original.

25 - Finished casting is flexible and much safer for stage than the solid wood original.

                   
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