How to Make Prop Swords out of Flexible Foam


Production companies regularly contact Smooth-On looking for an easy way to reproduce multiple prop weapons for stage and screen. These props are often used by extras in large battle scenes and must be easy to carry and safe to use. Smooth-On's FlexFoam-iT!® expanding flexible foams make an economical and safe choice.

This tutorial shows how to cast a FlexFoam-iT! 25 stunt prop sword into a Mold Max® 30 silicone mold. FlexFoam-iT! 25 develops a tough outer skin making it ideal for the finished piece. Smooth-On's Cast Magic® powders are a fast and easy way to add color and depth to any casting. The completed prop is lightweight, flexible and safe.

Materials Used in this Tutorial

Step 1: Prepare Mold