Tag Archives: casting

Specter Studios making a Foam Axe

There are only two more days to enter my contest to win a foam baseball bat. The bat is made by a Pittsburgh company called Specter Studios; they use local artists to create and fabricate all the props and costumes they sell. They happily shared some photographs showing the work they do.

Demolding an axe
Demolding an axe

They were not making any bats at the time, but they were building some fireman axes, which are made with a similar process.

Foam axes
Foam axes

The axes have a rigid rod buried within them. After they have the foam cast around them, they are sent off to have the colors airbrushed on.

Airbrushing the base coat
Airbrushing the base coat

So there you have it: making foam axes in the Steel City.

Airbrushing some red
Airbrushing some red

Lending a Hand to Titus

Our last show of this calendar year was Titus Andronicus, which, depending on the budget, could be a prop person’s dream or nightmare. Meghan Buchanan was the prop master on this show, and her company, Paper Mâché Monkey, was handling most of the acquiring and construction of the props. Since King Lear was winding down, I offered to lend a hand, and as luck would have it, they needed a hand. Jay O. Sanders hand, to be precise; after he cuts it off, it shows up in a later scene.

Mixing the alginate
Mixing the alginate

Life casting a hand is one of the easier parts to do; the only tricky part here was that they were rehearsing uptown at Second Stage Theatre and I only had an hour, so I had to prep everything beforehand so I could be in and out like a ninja hand caster before anyone knew what had happened.

Jay O. Sanders molding his hand
Jay O. Sanders molding his hand

I used alginate because it’s cheap, non-toxic, safe on the skin, and sets up quickly. It’s made from seaweed and used in dentistry to make molds of your teeth and gums. After mixing the powdered alginate with water and filling a hand-sized container, I asked Jay to pose his hand and submerge it. It doesn’t heat up like plaster; it just slowly thickens. In about ten minutes, it had solidified enough to where Jay could remove his hand. It’s stretchy enough that he could pull his hand out without breaking or tearing the mold (if done slowly), and it doesn’t really stick to anything (no mold release is needed). The little bit that does stick can be washed off with water.

Pouring plaster in the alginate mold

The thing with alginate is that it starts shrinking right away as it loses water. You only have about two or three hours to make a cast before it has shrunk noticeably. I mixed up some plaster while still at Second Stage and poured it in. After it had hardened enough, I packed up my stuff and took the subway back down to the Public Theater.

Plaster hand inside the alginate mold
Plaster hand inside the alginate mold

Now I could just tear the alginate away until the plaster hand was free.

Brush-on mold
Brush-on mold

I decided to do a brush-on mold for this because of the shape of the hand. I had only attempted a brush-on mold once before and it didn’t go so well. This time around was only marginally better. I ended up making it work, but that’s about the only good thing I could say. After the rubber mold set, I built a two-piece plaster shell around it for support. I ended up having to cut open some of the silicone mold to remove the plaster hand inside.

Unpainted silicone rubber hand
Unpainted silicone rubber hand

I cast the hand itself out of Smooth-On Dragon Skin, which long-time readers may remember being used in both the dead body and head for The Bacchae, as well as the dead lamb for Little Foxes. Dragon Skin itself cures fairly translucent and colorless, so I tinted the whole mix with a flesh color. I also embedded some dowels inside to cut down on the amount of silicone rubber I would need and to act as bones.

Hand of Titus Andronicus
Hand of Titus Andronicus

I “painted” more Dragon Skin over top, tinted with different colors. I rubbed some darker colors into the cracks and crevices to give it a bit of depth, and added a bluish tint onto the veins. I was using a fairly thick mix so it wouldn’t run. Silicone rubber is self-leveling unless it is thickened, and it can be pretty glossy if allowed to do that. I didn’t want that on the hand, but I took advantage of that for the fingernails, where I used a pretty thin mix and only a touch of color to get a shiny and translucent effect.

"I kind of feel like that kid who found the severed hand..."
"I kind of feel like that kid who found the severed hand..."

The hand has gone through some changes since I took these pictures; the bones on the back were cut down in length, and a lot more blood was painted on. All told, it only took about three days between them asking me to lend a hand making a cast of a hand to the cast having a hand in hand for rehearsal.

Review: The Prop Builder’s Molding and Casting Handbook

The Prop Builders Molding and Casting Handbook
The Prop Builder's Molding and Casting Handbook

In Thurston James’ second book, he tackles the subject of molding and casting for prop makers in more detail. The Prop Builder’s Molding & Casting Handbook guides you through the most common materials and methods used in many prop shops. Because of its specific focus (and better organization), this book is far more successful than his previous Theatre Props Handbook, which, as I mentioned in my review, meandered through disparate topics with no way to quickly find information.

Though written in 1989, the methods described in this book still hold true today. Though the range of materials we can use today have grown dramatically, they remain improvements and new formulations to older materials whose predecessors can be found in this book.

It remains one of the most widely recommended books for molding and casting props because of the unique niche it fills. It describes the most common materials and methods used in props shops and by hobbyists; these materials are used because of their cost, ease of use, availability, and proven results. Books on molding and casting for manufacturing and industry are more focused on specific or specialized materials, and they aim for a level of consistency and cost efficiency which the prop artisan would never possibly need. Shaving a tenth of a cent off the cost of a casting makes a difference if you are casting ten thousand pieces, but it will be impossible to notice if you are only making ten.

James seems to have had an epiphany in shop safety between this book and the last, as he now presents clear and accurate safety precautions in the beginning of the book, and continues to reiterate them throughout. In his Theatre Props Handbook, safety precautions were nearly nonexistent.

The book does a good job of covering the generalities of mold making and casting. It discusses the model and its preparation, and defines a number of necessary terms, such as undercuts, release agents, mother molds and the like. It describes the considerations of making a mold of your specific piece, and breaks the various molding materials and casting agents into categories. In a way, it describes the process of choosing your materials in an almost flowchart-like manner. If you know what your model looks like, and you know what kind of properties and appearance your castings need, then you can narrow your choices of mold material and casting material down to a few choices. In the book, he describes over thirty of these material choices.

The bulk of the book is used to guide you through the specifics of working with each of these materials. Specifically, he talks about plaster, alginate, latex rubber, and silicone rubber (RTV) mold-making. The casting materials he describes include latex, neoprene, papier-mâché, Celastic, fiberglass (GRP), hot melts (such as wax, plasticine, hot melt glue and hot melt rubber, breakaway glass, thermosets (specifically polyester resin), water-extendable polyester, and urethane. He also has a section on casting with hardware store products, like caulk, autobody filler, water putty, and several others. Finally, the last section of the book describes vacuum forming and how to construct a vacuum forming machine.

Behind the Scenes of an Opera-House, 1888: Constructing a God

The following is an excerpt from “Behind the Scenes of an Opera-House”, written in 1888. The author, Gustav Kobbé, tours the backstage of the Metropolitan Opera in New York City. Be sure to check out the previous excerpt when you are finished here! The following details the construction of a large idol for the Met’s 1888 production of “Ferdinand Cortez”. As an added bonus, you can read the original New York Times’ review of that production.

Behind the Scenes of an Opera-House, by Gustav Kobbé.

[T]he property-master had made out a list of the articles to be manufactured in his department. He had not been hampered by the problem of historical accuracy. He found drawings of Mexican antiquities from which he made sketches of the Mexican implements of war and peace to be used in the opera, and from a genuine Mexican relic of that period, seen by chance in the show window of a store, he obtained his scheme for the principal property in the work, the image of the god Talepulka. He found he could have all these historically correct, except that he did not think it necessary to go to the length of decorating the idol with a paste made from a mixture of grain with human blood. A problem arose, however, when he considered the construction of the idol. He ascertained from the libretto that the idol and the back wall of the temple are shattered by an explosion, and that, just before the catastrophe, flames flash from the idol’s eyes and mouth. He consulted with the gas-engineer, who had already considered the matter, and concluded that it would be most practical to produce the flames by means of gas supplied through a hose running from the wings.

The property-master then made the following note in his plot book: “Flames leap up high from the heathen image—the gas-hose must be detached and drawn into the wings immediately afterward so as not to be visible when the image has fallen apart.” The necessity of having the gas-hose detached determined the method of shattering the idol. It is a theatrical principle that a mechanical property should be so constructed that it can be worked by the smallest possible number of men. This principle was kept in view when the method of shattering Talepulka was determined upon. The god was divided from top to bottom into two irregular pieces. These were held together by a line, invisible from the audience, which was tied around the image near the pedestal. Another line, leading into the wings, was attached to the side of the top of one of the pieces. At the first report of the explosion a man concealed behind the pedestal, whose duty it also is to detach the gas-hose, cuts the line fastened around the idol, and the pieces slightly separate, so that the image seems to have cracked in two jagged pieces. At the next report a man in the wings pulls at the other line and the two pieces fall apart.

The manner in which the effect of flames flashing from the eyes and the mouth of Talepulka was produced was only outlined in the statement that it was accomplished by gas supplied through a hose. The complete device of the gas-engineer, a functionary who in a modern theatrical establishment of the first rank must also be an electrician, was as follows: Behind the image the flow of gas was divided into two channels by a T. One stream fed concealed gas-jets near the eyes and mouth, which were lighted before the curtain rose and played over large sprinkler burners in the eyes and mouth. These burners were attached to a pipe fed by the second stream. When the time arrived for the fire to flash, the man behind the pedestal turned on the second stream of gas, which, as soon as it issued from the sprinkler-burners, was ignited by the jets. By freeing and checking this stream of gas the man caused the image to flash fire at brief intervals. Thus only two men were required to work this important property.

Constructing the "Talepulka" prop
Constructing the "Talepulka" prop

The idol was but one of four hundred and fifty-six properties which were manufactured on the premises for the production of “Ferdinand Cortez,” and when it is considered that the average number of properties required for an opera or music-drama is three hundred and fifty, it will be understood that the yearly manufacture of these for an opera-house which every season adds some three works to its repertoire is an industry of great magnitude. For instance, one ton and a half of clay was needed for modelling the Mexican idol, and that property represents three months’ work. It was first sketched in miniature, then ”scaled”—that is, projected full size on a huge drawing-board—next modelled in clay, and then cast in plaster. The modelling and casting of properties are done in a room in the basement of the building, on the o-p-side [Eric: opposite-prompt side, in this case, stage-left] of the stage. The idol was cast in twenty pieces. These were transferred from the modelling-room to the property workshop on the third floor of the building, prompt side, where are also several other rooms in which properties are made, the two armories, the scenic artist’s studio, and the property-master’s office. In the workshop the properties are finished in papier-maché, the casts being used as moulds. They are not filled with pulp, which is one method of making papier-maché, but with layers of paper. The first layer is of white paper, moistened so that it will adapt itself to the shape of the cast. Layer after layer of brown paper is then pasted over it. The cast having been thus filled is placed in an oven heated by alcohol, and baked until the layers of paper form one coherent mass the shape of the cast. Properties thus manufactured have the desirable qualities of strength and lightness.

First printed in “Behind the Scenes of an Opera-House”, by Gustav Kobbé. Scribner’s Magazine, Vol. IV, No. 4, October 1888.

Midweeks Link Dreams

Just a reminder that today at 2pm (EST), I’ll be taking part in a live chat interview at TheatreFace. Come join in the fun if you want to ask me a question.

I also have a fun new project I’ve been working on, and I might be posting photographs of it as early as next week, so stay tuned. Until then, here’s a fresh roundup of links for you to explore.

  • You know that Smooth-On has a plethora of videos and tutorials on their website, right? Well now, they also have a Mold-makers Exchange, where you can buy or sell molds and casts, or advertise your mold-making services. It’s like a Classifieds for all things moldmaking (or a “Craigslist” as the youngsters (and I) say). It’s very sparse at the moment, which is why I’m getting the word out about it.
  • The Library of Congress has a YouTube. With nearly 600 videos from their archives, there is a wealth of historical material available for free viewing. Many of these videos are great for research on the early twentieth century and thereabouts.
  • Check out these delicious fake food miniatures.
  • Erich Friend runs a Theatre Safety blog. Though focused more on theatre planning and operations, some of the information (I’m looking at you, hidden fire extinguishers) is relevant to props shops.
  • And finally, Volpin Props has made an awesome M8 Avenger Assault Rifle out of scrap materials he had sitting around in his shop.