Sometimes we help our customers achieve a higher detail for their costumes. This project was based on turning a 3D model into flexible pieces that can be bent around curved shapes.
We 3D printed the files on our Prusa MK3s printers at ultra high detail. The pieces were then sanded using various grits of sand paper, coated with Bondo spot filler and sprayed with Rust-oleum filler primer. This process was repeated until the pieces were smooth enough for a coat of Triple Gloss Clear Coat. The pieces were then glued to a piece of glass and mold walls were made. The entire assembly was sprayed with Ease Release 200 which acts as a mold release and helps the silicone not stick to the piece or walls of the mold. Mold Star 20T platinum silicone rubber was used to create the mold. These pieces were put in a pressure pot to cure without bubbles at 60 PSI.
Once the molds cured, the original 3D prints were released from the molds and mold walls. The rubber molds were cleaned with soapy water and sprayed with a new layer of Mold Release 200. Since we are going to be casting silicone pieces in a silicone mold and silicone only sticks to silicone, it is vital we do a thorough job making sure the molds are sprayed with mold release evenly. The pieces were cast in the same material as the molds and dyed black using Sil-Pig from Smooth-On. A pressure pot was used again to eliminate bubbles in the final casts.
This process was repeated until enough casts were produced. Final photos were sent to the customer and shipped safely to their home.
