Use Hotglue As a Casting Material




About: I build products which solve real world problems.

Did you want to use your Hotglue as a casting material? Its very cool!

The "spiderweb" design on the hilt is craft foam strips coated with a thin layer of hotglue, and the skull is an ornament I cast using hotglue which I poured into a silicone mold.

Here's how I made the skull.

Step 1: Making the Model Ornament

I began by making the model ornament out of modeling clay and then I mixed and poured silicone over that to get my mold. (The clay got kind of smushed up as I removed the mold...)

You can make it according to your needs.

Step 2: Casting the Model

Casting with hotglue is a very tricky business because bubbles love to form in it when it's warm. To eliminate bubbles, I put the nozzle of my gluegun close to the bottom of the mold and started squeezing slowly.

I went over the entire bottom of the mold, making sure all of the crevasses and spaces had been completely filled. If any bubbles formed anywhere within the mold, I took a pin and pricked them. I had to do it quickly, before the glue started to cool and set.

Step 3: Cooling the Mold

I set the mold in the freezer and, after a few minutes, the hotglue had completely cooled. I was then able to remove it from the mold. (It popped out rather easily. I love silicone.)

I inspected the surface of the cast object to check for holes or gaps in the surface which had failed to be filled in. These could be dealt with, but it took a bit of artistry to close the holes and build up the surfaces and features that needed to be built up. Obviously, the more practice one has working with hotglue, the easier this type of thing is. After the hotglue had cooled, I took some hobby sandpaper and ran it over the surface of the skull ornament to even it out, (ie: make the newly added glue look just like the cast glue.)

After I was satisfied with the look of the skull, I hotglued it into place on the hilt

Step 4: Final Touches

After I was satisfied with the look of the skull, I hotglued it into place on the hilt. And then just painted it as I would any other surface. (Antiquing it in this case, using a mixture of black and silver enamel.)

So there you go. Why waste time, money and effort casting an object in resin if you can make one that looks just as good (and is almost as strong) out of hotglue? About the biggest problem you'll face casting with hotglue are the airbubbles that can arise in the interior and surfaces of your objects. You'll have to be diligent about popping them, and about making sure that your hotglue fills up ALL PARTS of your mold.

Congrats! You made your own design by molding using hot glue!



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    13 Discussions


    Reply 3 years ago on Introduction

    Go to

    and check out the Quick-Set rubber mold making materials. For longer-setting silicone rubber molds I recommend the Alumilite HS3 (High-Strength level 3) silicone rubber mold making material. It's expensive, but captures detail extremely well.

    Setting time takes about 18 hours, depending on the size of the object from

    which you want to make a mold.


    3 years ago on Introduction

    Awesome idea casting hot glue. But, won't the hot-glue cast object melt

    under high temperature conditions?

    (ie: Inside a non-airconditioned room on a hot summer day, or exposure

    to direct sunlight)


    3 years ago on Introduction

    I bet if you had a two part mold, pre-warmed, you could injection cast with a hot glue gun. Would be an interesting experiment if nothing else.


    3 years ago

    Use a glue gun with a precision tip to reduce bubbles.
    It is also possible to bake your silicone mold at about 250F to release the bubbles, but this is an extreme case.


    3 years ago

    Cool project. Thanks for sharing.


    3 years ago



    3 years ago on Introduction

    I never thought to use hot glue as a cast. Such a great idea, and your images speak for themselves! That skull is amazing!


    3 years ago

    Great job!