Creating Lightweight Theatrical Costume Armor

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

1 - Alja-Safe® alginate is used to take an impression of the actor's chest.	2 - Gypsum bandages are used to back up the alginate and provide support.	3 - The Alja-Safe® captured every detail of the actor.
4 - A gypsum cast is made from the Alja-Safe® mold.	5 - The armor detail is sculpted onto the gypsum positive using oil-based clay.	6 - Moldmakers apply a thin coat of Rebound® 25 rubber.
7 - A thickness of 3/8'' (1cm) of Rebound® 25 silicone is brushed onto the sculpt.	8 - Plasti-Paste® is applied on top of the cured Rebound® 25 to form a support shell.	9 - The Plasti-Paste® is allowed to cure.
10 - The mold is opened, all detail has been catured in the Rebound® 25 silicone.	11 - Cast Magic® powder is brushed onto the mold surface.	12 - Smooth Cast® 325 is pigmented black using So-Strong® tints and brushed into the mold.
13 - The Smooth Cast® resin is allowed to fully cure for 1 hour.	14 - The finished resin casting is a perfect fit.