Final Moulding: Clariel

Hey guys! I am really excited and nervous today. I’m using my brand new vacuum pump and taking the final mould for the Clariel model sword. (I hope.) It has taken way longer than I thought to get that plaster sword prototype as smooth and shiny as I possibly can.

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The glossy varnish I have needs about 12 hours to fully set before I can put on a second coat so you can imagine how long it took to get multiple coatings on and then polish the thing.

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I think it was worth the extra effort. 🙂

Now, the next step is getting it fitted into the moulding box nice and snugly. That took a long time as well. Why? Because you saw how sloppy my first mould was. Let’s not have a repeat of THAT nonsense! We want the two halves of the mould to line up all straight and smooth and beautiful so that I can easily clamp them together with no leaks or weird seams.

To do that, I have to find the exact middle of the object I’m taking a mould of. That’s tricky when it doesn’t sit flat on the table. It’s chubbier in the middle than it is at the point of the blade or the pommel (butt end). So that makes it do a see-saw thing when I try to lay it flat. To compensate for that, I have to put a cushion of clay under the blade and the handle to make it sit perfectly level. Then, I have to cut a piece of laminated foam (or anything else that’s flat really … could be wood but I used foam) to fit in the space between the sword and the edges of the box. That’s so the silicone doesn’t fall down through any gaps and fill the whole darned box. That would trap the sword inside and I’d be really sad. (Hey! Give me my sword back!)

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And that gives us exactly one half of Clariel to make exactly one half of a mould. Yaaaay!

But what’s all that green stuff in there? No one said there would be green stuff aaahhhh! Don’t worry. that’s just clay. Some of those clay noodles are touching the sword and some aren’t. The ones that are touching Clariel are air vents. Those allow the bubbles to escape from the resin when I pour it into the mould so (hopefully) they get out of the sword and don’t get stuck in there.

The noodles that aren’t touching the sword are what we call “findings”. You know when you’re closing a plastic container of leftovers and putting it in the fridge for later? Take a look at the lid sometime and you’ll see there’s a trench all the way around where it fits over the edge of the container. That makes a nice snug fit so air doesn’t get inside and so you know the lid is in the right spot before you push down on it for that nice satisfying “click!”. Container closed and ready to go. Like your plastic sandwich box, the two halves of the mould need to fit together nicely and the findings help you figure out when both sides have lined up just right.

And then I pour 300 Euros of silicone into it. Haaaaah … yeah send me Luck runes guys! You can probably see why I’m a little nervous of screwing up! Haha!

Well, that’s enough procrastinating for me. I’d better go Iron Brother it up in the workshop. (I’m just kidding. I love talking to you guys. LOL) Oh, and if you’re a Matthew Daddario fan like me, don’t forget to wish him a happy birthday if you haven’t already!

Ciao for now!

A Pure White Blade

What an amazing ride last week was! Here’s where we left off with my last update:

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That’s the second prototype of Clariel curing in its silicone and plaster jacket. No way of telling if it worked or not. If it cured all the way through. If it cured with giant bubbles in it … So, it’s time to reveal what was hiding in that plaster cast.

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Ahhhhh it worked! It worked! It’s really rough on the surface there but the plaster is solid all the way through and the imperfections that are there are really small.

Let’s take it out of the mould.

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Aw yeaaah! Hello me beauty! I’d recognise that shape anywhere. No time to gloat though; let’s get sanding.

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Ah, now that is just a lovely sight to behold. You can see a shift in colour where the handle is because I poured the plaster in two stages. Plaster cures with an exothermic reaction. That means it gives off heat while it’s hardening. I didn’t want to overwhelm the rather shoddy mould I’d made so I decided to do it in two pours instead of just one. Next time, I’ll do it all in one go as I’m more confident that the materials can take it.

There are tiny imperfections on that blade though I really doubt you can see them. I vibrated the mould while it was curing to jiggle the air bubbles up and out of the plaster so there really aren’t many bubbles and the ones that are there are really small. Still, this prototype has to be perfect. Any imperfections left will be present in every Clariel from now until I make a new mould.

The Iron Sisters aren’t known for their “okay” craftsmanship. 😉 I demand excellence!

This week, I am correcting the remaining errors in Clariel prototype 2.0 with a very fine spackle and … yeah … more sanding. Then it gets sealed and polished up just as shiny as I can make it. Then, we take a mould with the expensive professional moulding silicone. That mould will be the one that makes all my Clariel swords from now on.

Yes I’m terrified but hopefully we’ll have just as much luck as we had last week! Cross your fingers for me folks.

That’s all from me for now. See ya later!

Learning Experiences

Wow! This past week has been a steep climb for me with learning the skill of mould making. I’m beginning to understand exactly why there are no commercial manufacturers of Seraph Blades. Let me tell you a bit about why the project is logistically really demanding.

If you’re going to cast something crystal-clear and bubble-free, typically, you’d want it to be small enough to fit in a pressure pot. Those are about the size of a big ol’ soup pot. As you’ve already guessed, no dice for me. Perhaps little wee Remiel would fit, but everything else is too big!

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The best resin for casting beautifully crystal clear objects is PMMA (acrylic resin). That’s a polyester resin and those are notoriously stinky. Like, not only will you have a headache but so will everyone else in the building kind of stinky. Obviously these kinds of castings are done in purely industrial environments where you can have your workers in protective suits and a nice big, badass air filtration chamber to keep that stench locked down.

I have a workshop sandwiched between a tailor’s shop and a ceramics maker. Again, no dice. I have to pick something that’s not horrifically smelly. See what I mean when I say that 95% of my job is problem solving? Hehe, I wasn’t kidding.

But it’s not all doom and gloom guys! I’ve got stuff to show you.

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That is the inside of the silicone mould I made. It seems that the mould release agent I got didn’t work. On the right side, I used wax, and that worked rather well. On the left, I used a spray-on release agent and … uh, well it ripped almost all the paint and some of the foam off the prototype that I made. (That prototype is NOT in good shape right now and I really hope I don’t have to take yet another mould of it cause I dunno if it will survive!)

Now, as you can see, the bottom of the mould stuck together. That’s not a deal-breaker and I know why it happened. I should have used probably about a half tube or a full tube more silicone per side than the amount I used. Whoops! But I had no idea how much it would take so I had to guess. So the silicone mould is thinner than I would like it but on the upside, I now know the exact amount of silicone to use for making the final mould. That’s really valuable information because professional grade silicone is really expensive! I paid over 300 euros for just 10kg of it. Aren’t you glad I’m not making your swords out of silicone?! No one would be able to afford it!

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Now here is the silicone mould clamped firmly in its plaster jacket. The rigid jacket is necessary to force the floppy silicone to hold its shape while I pour in the plaster. Yes, more plaster. Not resin just yet, because the prototype that I take the final mould of must be perfect. Any mistakes I make with that last prototype will be present in every single sword that comes out of that mould.

Now, there are some things that have me worried about this setup. 1. I forgot to put in an air vent so I’m going to have to pour super slowly. That means mixing the plaster in small batches and putting a lot of water in it.

What can go wrong? There is air in the mould. Of course there is! There’s air in the rest of the room too, haha! And when I start pouring in plaster, that air has to burp out somewhere or it will get trapped inside the mould. Annnnd that means the prototype sword that comes out will have holes in it where the bubbles were. Boo! We want holy swords not holey swords. (Okay that pun was awful, I’m sorry.)

2. I’m worried that the plaster might leak out of the mould all over the place. This mould is ugly, cheap, and very lumpy. It’s not nice and flat and easily clamp-able like it should be. And that’s okay. I only need it to work once. But it has to work at least once!

This is the principle of Rapid Prototyping. Use cheap materials and quick techniques to yield progressively better results until you’re satisfied with the final product. I’ll talk more about rapid prototyping later for all you enterprising prop-makers. 😉

3. I’m not really happy with the type of plaster I’m using right now. I’ve used a German brand (Knorr I think?) before and it took absolutely beautiful and accurately detailed moulds and I think that might be the kind I want to use for this. The kind I have (you can see it sitting in baggies in the picture of the silicone mould) is very thick unless you add double the amount of water it says on the package. It also cures really fast.

That’s great for things like making the hard jacket for the mould. I don’t need that to pick up fine details. I just need it to be done quickly and strong. So I’m not miffed that I bought a bunch of it form the hobby shop. I just don’t trust it to do what I need it to do for a prototype.

But the brand that I like is more expensive. (Story of my life.)

So what happens if this moulding doesn’t work? Well … the Iron Brother takes a deep breath and lets it out slowly (probably with a stream of his favourite cuss words) and starts the process over again. At that point, I have two choices. 1. I fix up the foam prototype and do the mould-making again from that without making the same mistakes that I made with this mould. (Too little silicone. Wrong mould release. Plaster jacket not straight and flush. Forgot an air vent for the bubbles.) or 2. I go with my original idea of crafting a perfect prototype first with a wooden core and polymer clay exterior polished to a high shine and coated in high-gloss varnish.

Which will I choose? That depends on exactly what kind of screw-ups happens with this casting! We’ll find out today folks. Are you excited? I’m terrified. Let’s go! Wheeeee!

 

Clairel: First Moulding

I started writing this post yesterday and then realised I didn’t have a picture for you! Durrr … That’s not nearly as exciting without a pic.

So you can see my first Clariel prototype (carved in foam) in there, covered in latex and ready for its hard casing to be put on. The casing is already on there now but I forgot to snap a photo before I left the workshop yesterday. (Cause I’m brilliant like that. XD )

I’m really hoping I did everything in the right order. BUT if I didn’t, it’s okay. I can always do it again.

Remember: if you failed but you learned something, you haven’t wasted your time!

Clariel Model Prototype

Ahhh yeah. It took me a couple days to carve the prototype for Clariel. Now I can take the first mould of it. After that, we move on to the second prototype which will be made of plaster. I’ll be able to get a much, much smoother surface with higher detail with plaster.

Also! Special news!

I’m moving to a new workshop! Don’t panic. It’s in the same building on the same floor so it won’t take long. Probably a day or two. This new room is a bit more expensive but it’s also a bit larger and has a couple windows.

I decided to take on this added expense for the sake of having a window so that I can have fresh air and natural light to work with. Alumilite is a very low-smell resin but it’s still recommended to have fresh air when working with it. I’ll post pics as soon as I’m able.

Until then, stay safe out there Shadowhunters.

OOOOWWWWW! Darnit!

Yes, I know. I went quiet again. Thing is: I cut the tip off my left ring finger by accident. Well, of course it was an accident. I’m not that bonkers.

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Now, it’s healing quite well. Got some nice pink new skin coming in and I should have full function of my finger, but the wound is still fresh enough that I still can’t do any carving without it … uh … well, leaking. Ewwwww. No I’m not gonna show you any pics of the boo boo itself. That’s gross.

I go on vacation to Canada to see my friends and relatives that I haven’t seen for two years. I had hoped to have the sword model finished and moulded in silicone, ready for resin casting when I got back. Needless to say, that’s gotten pushed back.

It’s frustrating. I get a new request for a sword pretty much every second day and I really, really want to be making all those pretty shiny things for y’all right now! This is just rotten luck I tell ya. I’m super duper bored cause, well, it’s my finger. Everything I do requires the use of both my hands. Even typing is weird and slow because I can’t push the W, S, or X button with the finger I’m supposed to.

Anywho, grump grump grump, pout pout pout, rawr. I swear I’m not being lazy. I’m just full of OUCH. Yes I will get to your emails. Thank you for being patient with me. Stay awesome. ❤

Breaking New Ground

Yeah, I’m still healing. Yeah, it’s taking a frustratingly long time. But! I have enough stamina to do a little light work each day so I’ve been whittling away at the model I’m going to be casting.

Wooden Sword

Recognise the model? It’s Clariel! This is the sword type that most people request when they email me so I decided to make it the first mould I do for the resin casting.

It’s still looking quite chunky because I’ve only got the outline cut out so far. The next step is to shave down the sides into the right shape.

I’ll try to keep y’all updated as I go. Sorry I’ve been quiet. I’m trying to save most of my energy for actually making the thing. That’s the important bit after all!

I’m hoping to have this model completed and moulded before I leave for summer holidays at the end of this month. I haven’t seen my friends and family in Canada for a couple of years so I figure you’ll forgive me a little break eh? Heheh!

Wish me luck everybody! I can’t wait to be back to work full time.