Cosplay Tutorial: Iron Man Helmet – Part 2: 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 mould or jacket) using the EpoxAmite laminating epoxy system. We then cast this mould 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 mould was made for this project.

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