Cosplay Tutorial: Iron Man Helmet ‑ Part 2: How To Make an Epoxy Support Shell and Hand Rotated Casting


In this mold making how to video, we demonstrate how to make a lightweight and durable epoxy fiberglass support shell (also called a mother mold or jacket) using the EpoxAmite laminating epoxy system. We then cast this mold by hand rotating (or slush casting) Smooth-Cast 57D impact-resistant urethane resin. Just how durable is Smooth-Cast 57D? Jump to 17:13 to see a 30ft drop test. In Part 1 we demonstrated how the Rebound 25 silicone glove mold was made for this project.

Materials Used in this Tutorial

  • EpoxAmite 102 Laminating Epoxy
  • Fiberglass Fabric
  • Mixing Sticks and Containers
  • Chip Brushes
  • Smooth-Cast 57D Urethane Resin
  • So-Strong BLACK Tint