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Creating Lightweight Theatrical Costume Armor
Andreas Moravec is a moldmaker and makeup artist based in Austria.  In this photo sequence, Andreas demonstrates a technique for creating '300' style theatrical armor using Rebound 25® silicone and Smooth Cast® resins

Using Smooth Cast® 325 pigmented with So-Strong® black tint produces a very lightweight, yet impact resistant piece.

Visit Andreas' website here: http://www.andreasmoravec.at
 Alja-Safe® alginate is used to take an impression of the actor's chest.

1 - Alja-Safe® alginate is used to take an impression of the actor's chest.
 Gypsum bandages are used to back up the alginate and provide support.

2 - Gypsum bandages are used to back up the alginate and provide support.
 The Alja-Safe® captured every detail of the actor.

3 - The Alja-Safe® captured every detail of the actor.
 A gypsum cast is made from the Alja-Safe® mold.

4 - A gypsum cast is made from the Alja-Safe® mold.
 The armor detail is sculpted onto the gypsum positive using oil-based clay.

5 - The armor detail is sculpted onto the gypsum positive using oil-based clay.
 Moldmakers apply a thin coat of Rebound® 25 rubber.

6 - Moldmakers apply a thin coat of Rebound® 25 rubber.
 A thickness of 3/8'' (1cm) of Rebound® 25 silicone is brushed onto the sculpt.

7 - A thickness of 3/8'' (1cm) of Rebound® 25 silicone is brushed onto the sculpt.
 Plasti-Paste® is applied on top of the cured Rebound® 25 to form a support shell.

8 - Plasti-Paste® is applied on top of the cured Rebound® 25 to form a support shell.
 The Plasti-Paste® is allowed to cure.

9 - The Plasti-Paste® is allowed to cure.
 The mold is opened, all detail has been catured in the Rebound® 25 silicone.

10 - The mold is opened, all detail has been catured in the Rebound® 25 silicone.
 Cast Magic® powder is brushed onto the mold surface.

11 - Cast Magic® powder is brushed onto the mold surface.
 Smooth Cast® 325 is pigmented black using So-Strong® tints and brushed into the mold.

12 - Smooth Cast® 325 is pigmented black using So-Strong® tints and brushed into the mold.
 The Smooth Cast® resin is allowed to fully cure for 1 hour.

13 - The Smooth Cast® resin is allowed to fully cure for 1 hour.
 The finished resin casting is a perfect fit.

14 - The finished resin casting is a perfect fit.

                   
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