Learn How to Make a Two Part Mold And Cast Crystal Clear Medieval Knight Action Figures

Step 1: Prepare the Knight

First Push the Knight into clay and shape the clay so that half of the Knights body is covered in clay. This is a very important step if you want to minimize seam lines and control how the two parts come together.

Then place the Knight into a mold box. I glued a lid onto the deli container and cut a slot for pouring.

At this point spray or brush on a mold release. I did not use a mold release Because the Knight has a smooth texture and is unlikely to stick to the mold.

Next spray a medium coat of Bubble Buster. Bubble Buster is great for reducing surface tension and preventing bubbles from sticking to objects.

Step 2: Create the Mold

While the Bubble Buster is still wet, pour the melted ComposiMold until it covers the entire exposed half of the Knight. ComposiMold can be melted in the microwave a double boiler or a chocolate melter.

This mold took about three hours at room temperature before I could remove it from the mold.

Before pouring the second half, remove the clay, coat it with mold release and cool the first half. Wait until the liquid ComposiMold has cooled but is still pourable before pouring it over the first half. The ideal pouring temperature is between 120 to 135 F.

As you can see the mold separates nicely and the detail is perfect!

Step 3: Duplicate!

Now it’s time for the resin. For this project I used clear casting plastic which is a two part epoxy resin that when cured it becomes a rigid transparent plastic. The two parts are mixed equally with a 1 to 1 mix ratio by weight or volume.

To guarantee a bubble free part carefully measure and mix the two parts.

Once the two parts are thoroughly mixed prepare to inject the resin into the mold. I chose to poke a hole at the top of the head but you can also start at the foot and let the material rise.

Fill the syringe and inject the resin until the mold is filled. If there is a trapped air bubbles, stick a nail through the mold and guide the bubble out especially at the top of the head.

The resin should be left for at least 14 hours before removing from the mold, and it will take about 3 days for it to completely cure.