Step 1: Create Character from Clay
Make the first generation from clay. Concept sketches and preliminary models always help. Always keep in mind the next step when
designing an action figure that must be molded and reproduced.
Step 2: Divide Joints and Make Seams
Determine from which plane the most detail is desired (Use the pic to the left to see how to make action figures have the most detail).
Section off broad curved planes with something like thin contact paper. Make sure the clay is lubricated so that the
mold material comes off with ease.
Step 3: Make Mold in Plaster
Spatter clay with plaster mixture, dripping into small detail creavases. No air bubbles is ideal
for first coating. Continue to build up plaster mixture until it is rather thick. Glob on remainder
and let dry. The mold will heat as it dries. After sufficient time has passed, split the mold apart.
Carefully remove the clay and gently clean.
Step 4: Cast Mold in Hot Glue
Carefully lubricate the mold with a swab. Make sure the hot glue gun is hot
and there are many extra glue sticks on hand.
First, fill all of the details in plaster mold with hot glue.
Stick wires through the center axis of each one of the joints, and
glue those into place. Braided wire works the best.
Since this is not an injection mold, care must be taken to
align the mold halfs. The molds must be flush and even. Manually trigger and push feed the hot glue gun and fill both sides completly around the seams.
Press the mold halfs together and flip occasionally to make sure the glue binds evenly with itself and there are no
holes. Mold all appendages seperately, keeping the body in two halfs.
Step 5: Paint and Assemble
Wash pieces clean of oil and debris. Clean rough edges and seams with a hot razor blade.
After painting, the wires can be tied in the center, and then the body can be glued together.
Variations:
prototype can be cast in latex. A permanant mold can be attained by
coating the latex in a ceramic compound and firing the ceramic mold when it is hardened.
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