Justin Jotso of Jester Productions and FX (Alachua, FL) needed materials to make a replica Captain America helmet from the recent film for a customer. He shared his mold making and casting process  with us using Rebound® 40 silicone rubber to make his mold and Free Form® Air Epoxy Putty to make the rigid support shell.

The Rebound® 40 mold was used to make 2 different versions of the helmet - rigid and flexible. The first helmet needed to be rigid and have a paintable surface for display purposes. Justin utilized EpoxAcoat® RED Surface Coat Epoxy that was then laminated using layers of EpoxAmite® 101 FAST Laminating Epoxy and fiberglass. The fully cured helmet was primed and painted. The second helmet needed to be worn as part of a costume and needed to be flexible, durable and paintable. A surface coat of Smooth-Cast® 65D semi-rigid urethane resin was backed up with VytaFlex® 40 urethane rubber to achieve these characteristics.

When asked about his experience with the materials used Justin said, "I'm switching all my molds over to Rebound 40. It works great and the library life is amazing!" For more information, please contact Justin here: http://jesterfx.com/

Smooth-On Products Featured in Step-by-Step Tutorial:

  • Mold Rubber: Rebound® 40 Brushable Silicone Rubber
  • Rigid Support Shell: Free Form® Air Epoxy Dough
  • Colorant: Silc Pig® Color Pigments (for silicone)
  • Release Agent: Ease Release® 200
  • To make rigid helmet: EpoxAcoat® RED Surface Coat Epoxy (surface coat that is primed & painted when fully cured) & EpoxAmite® 101 FAST Laminating Epoxy (backup layers)
  • To make flexible helmet: Smooth-Cast® 65D Semi-Rigid Urethane Resin (surface coat that is primed & painted), VytaFlex® 40 Urethane Rubber (backup layers) & SO-Strong® urethane color tints