DIY Rotocasting

Rotational molding, also known as rotomolding, is a molding process for creating many kinds of mostly hollow items. The info is not specific to Classic Cylon Centurions, but SURE can be helpful for them and many, many others projects. Here you'll find various threads with great info from our members for the hobby of costuming.
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Sat Aug 06, 2011 11:35 pm

my helmet was from that mold ;)

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Very cool ......I don't just mean the helmet...The whole armor outfit is way cool!

We had a question in an earlier post....after the mold was made ....were the helmets rotocasted or hand slushed?


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Huttman
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Re: DIY Rotocasting

Post by Huttman » Sun Aug 07, 2011 1:50 pm

slushed and by hand are the same thing ;) as far as I know anyway
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Sun Aug 07, 2011 10:08 pm

Huttman wrote:slushed and by hand are the same thing ;) as far as I know anyway

Ok ....So.......You did yours by hand?
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Re: DIY Rotocasting

Post by Huttman » Sun Aug 07, 2011 11:34 pm

no, thats not my mold, a fellow i know makes those helmets, mine was one of them
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Re: DIY Rotocasting

Post by Big Al » Mon Aug 08, 2011 12:40 am

Huttman wrote:no, thats not my mold, a fellow i know makes those helmets, mine was one of them

Ok so You don't know if he casted them by hand or by machine?
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Re: DIY Rotocasting

Post by Huttman » Mon Aug 08, 2011 11:43 am

yes, by hand
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Re: DIY Rotocasting

Post by Cylon-Knight » Mon Aug 08, 2011 1:50 pm

So, for that Clone Trooper build Huttman... how are the "smoked eye insert" deal done? Is that Vacformed?
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Mon Aug 08, 2011 2:53 pm

Huttman wrote:yes, by hand
So it looks like the helmet came out nothing less than professional ....what would be the advantage of using the rotocast machine instead of casting by hand?

Would it be a matter of a more even distribution of resin through out the mold?

Less resin used? Maybe
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Skullbeast
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DIY Rotocasting

Post by Skullbeast » Mon Aug 08, 2011 2:59 pm

All of the above, and a human has to do the work not a machine (aka cylon).


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Re: DIY Rotocasting

Post by Big Al » Mon Aug 08, 2011 3:43 pm

Skullbeast wrote:All of the above, and a human has to do the work not a machine (aka cylon).


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Thanks Skullbeast!.....That's what I thought!.......When you make one by hand ....How long does it take to slosh and twist before the resin sets up?......Probably depends on the resin you are using huh? and one more question.....What type or brand of resin would you use for such a project? Fast cure, Slow cure,????
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DIY Rotocasting

Post by Skullbeast » Mon Aug 08, 2011 5:11 pm

BJB 808


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Re: DIY Rotocasting

Post by Huttman » Mon Aug 08, 2011 8:31 pm

Rotocasting that by hand is horrid on your back. My blaster mold is very heavy. I tried to do it by hand and almost pulled my shoulder.

As far as the eye lens, its a welders visor cut to fit.. There are other methods as well. I have bought lenses from motorcycle shops and cut them.
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Fri Aug 12, 2011 12:27 pm

:cylongold: Volpin Props



:cylon: Harrison Krix, a graphic designer and propmaker from Atlanta AKA Volpin Props and is a very talented guy who states very clearly he is a hobbyist and does not sell to many of his creations but in my opinion he is every bit as good as a hollywood veteran prop maker.

If you look at his links and his flicker account he has built many different props some from video games like the N7 gun from Mass Effect 2 and the two Daft Punk helmets and many more.

I have never seen a build that was so well documented!. The helmet builds he has done are the most intense, sophisticated, complicated helmet builds I have ever seen! His photos take you through every step from the plans to creating the plugs to the final product!... His Flicker account has over 1800 photos of his builds and all step by step.



:cylon: Time Elapsed Video of Volpin Daft Punk Helmet build that took 17 months and 749 steps Starting March 13 2009 and finishing July 17 2010




:cylon: Here is his Flicker Link that has high rez ref pics of this build.

Daft Punk Guy Manuel Helmet Build (195 Pics)

:cylon: Here is the Flicker link to the Thomas Helmet Build

Daft Punk Thomas Helmet Build (213 Pics)



:cylon: These are his Blog tutorial Links for the Daft Punk Helmet Builds

:arrow: Daft Punk Guy Helmet Part 1
:arrow: Daft Punk Guy Helmet Part 2
:arrow: Daft Punk Guy Helmet Part 3 Final


:cylon: This is the link to the Thomas helmet build

Daft Punk Thomas Helmet Part 1
Daft Punk Thomas Helmet Part 2


:cylon: These are worth looking at this guy uses every technique in the book to build his props! :salute:

This is a list of some of his Rifle and armor builds and the above link will open to the helmet build and have a clickable list of his other builds . This is amaizing stuff!!!

These Photo essay type tutorials are very HQ and detailed. this is worth looking at because this guy knows what he's doing.

:arrow: [url=http://volpinprops.net/2011/07/n7-rifle-mass-effect-3/]
Last edited by Big Al on Fri Aug 12, 2011 9:41 pm, edited 1 time in total.
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Fri Aug 12, 2011 8:20 pm

:cylongold: Material Supliers Links


:cylon: These are links to several Mold making, Silicone, Plastic and Resin Material Supliers.

The first one was recommended by Skullbeast..

:arrow: BJB Products Overview
:arrow: TC-808 Resin Data Sheet Pdf

:cylon: Here are some more

:arrow: Alumilite
:arrow: Freeman Supply
:arrow: Tap Plastics
:arrow: Smooth On
:arrow: Reynolds Advanced Materials
:arrow: Polytek Development Corp.
:arrow: The Engineer Guy
:arrow: Bity Mold Supply
:arrow: The Monster Makers
:arrow: Mold Life

I will post more as I find them
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Big Al
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Re: DIY Rotocasting

Post by Big Al » Thu Aug 18, 2011 12:02 am

:cylongold: Cylon Helmet Mold


:cylon: Here is one I found on the Worthopidia website and I thought you would like to see this


:cylon: Cylon Helmet Mold

[attachment=0]Cylon Helmet Mold.jpg[/attachment]

"Battlestar Galactica" (Classic) Cylon Centurion Head Master Mold

Original, Icons Master Mold taken off screen-used Cylon, intended for mass production of never-produced 1:1 scale licensed replica

Her e's a quite rare, original manufacturing artifact from the pioneering prop and miniature licensed replica company, Icons. It is a 2-piece, fiberglass jacketed, silicon production mold, created at Icons' North Hollywood, California facility in 1998 (14 years ago).

The condition of the mold is exceptional, other then a portion of the silicon, not present at the bottom portion of the jacket edge, on one side. We are NOT sugessting you use this mold to mass-produce Cylon Helmets.

As you can see by the photographs depicted below of this historical manufacturing artifact. It is a true testament to Icons legendary emphasis quality, which set a new standard in the licensed entertainment collectible industry. Which still effects quality standards in the Hollywood memorabilia replica and Toy collectible business to this day.

Icons staff consisted of numerous fans of the original cult classic Television series Battlestar Galactica. Who discovered, authenticated, archived and preserved numerous examples of some of the most scarce Galactica production artifacts ever found, including multiple, full-size Cylon robots from the TV series.

Icons was tfore provided rare access to an original Cylon costume, conducted extensive R & D, and proceeded to mold and master an original Cylon helmet, to create its Universal Studios licensed 1:1 scale replica. Complete with electronic red-eye and motion-activated sound effects chip.

Only 3 chrome-plated prototypes were ever produced and only 4 Cylon helmets casted. So this quality-made mold was used very minimally. In other words, it did not experience "mold burn-out" which usually occurs after "50" or more castings.

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