How to Cast Skulls With Silicone Molds

Written by alex smith
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How to Cast Skulls With Silicone Molds
Create resin skulls out of a silicone mould. (Jupiterimages/Photos.com/Getty Images)

There are two ways of making a skull out of a silicone mould: a solid pour and a hollow cast. Both methods use a two-part plastic resin, but differ in their execution. In the case of smaller moulds, pouring a solid skull is far easier and does not use much resin. In the case of a larger, life-size skull, it is more economical to create a resin shell and back it up with expanding foam.

Skill level:
Moderate

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Things you need

  • Skull mould
  • Silicone mould release
  • Straps, clamps or bolts
  • Disposable mixing cups
  • Craft sticks
  • Plastic resin, parts A and B
  • Scale or triple-beam balance
  • Polyfoam, parts A and B
  • Rubber gloves

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Instructions

  1. 1

    Spray all sections of the mould with silicone mould release. Allow the release to dry.

  2. 2

    Strap, bolt or clamp the mould together.

  3. 3

    Measure out parts A and B of a plastic resin product into separate disposable containers. The mixing ratio is typically 1:1, 2:1 or 1:2 by volume. Consult the instructions for the proper ratio.

  4. 4

    Mix the two parts together in one container and quickly stir them with a craft stick. Scrape the sides and bottom of the mixing cup to ensure complete mixing.

  5. 5

    Pour the mixed resin into the mould's pour spout.

  6. 6

    Allow the resin to harden. Most resins require 20 minutes or less.

  7. 7

    Remove the skull from the mould and sand off any plug left behind from the pour spout.

  1. 1

    Prepare and close the mould as outlined in Section 1.

  2. 2

    Mix a larger batch of plastic resin. Keep track of the amount that you use, you will likely have to tweak it over the course of the first few skulls until you find the proper amount. You want the skull's final resin shell to be between 1/8- and 1/4-inch thick.

  3. 3

    Pour the mixed resin into the mould's pour spout.

  4. 4

    Slush the resin inside of the mould, coating it evenly, until the resin solidifies. Do not allow the pour spout to be plugged closed.

  5. 5

    Slush another coat of resin into the mould if the first coat is too thin.

  6. 6

    Allow the resin to harden completely.

  7. 7

    Measure the A and B components of a rigid, self-expanding polyfoam in separate cups. Polyfoam is typically measured by weight, so you will need a scale or triple-beam balance.

  8. 8

    Mix the two components together, scraping the sides and bottom of the mixing cup. You must work quickly: the polyfoam will begin to expand in 30 to 60 seconds.

  9. 9

    Pour the polyfoam into the mould, filling the skull no more than 1/3 of the way. The foam will expand, filling the rest of the skull.

  10. 10

    Allow the foam to expand and harden, then remove the skull from the mould.

Tips and warnings

  • Resin and polyfoam both release toxic fumes as they cure. Work in a well-ventilated area.
  • Wear rubber gloves when working with resin and polyfoam.

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