How To Mold and Cast Foam Props!

Effects artist Frank Ippolito shows you how to make simple silicone molds to cast and paint foam replicas of props like shop tools! We go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects.

Shot by Joey Fameli and edited by Norman Chan
Music by Jinglepunks

Tested is:

Thanks for watching!

#FrankIppolito

[samusaran]

Watching this video is so fascinating because it feels like watching two people who have a life time of interviewing experience but have 0 chemistry so they carry the conversation with the correct things to say but it feels like such a lifeless performance.

[mesofun]

I make these type of props for film and TV. I wanted to point out that if someone is going to add a stiffener or something to make the handle ridged like in the axe, please do NOT add metal or a chopstick as they mentioned. If you are making these types of props for stunts that is dangerous. The wood can break and then becomes a sharp one that will hurt someone. Same with adding metal. I have found that using a fiberglass rod about 1/4" thick is a great option. To keep it safe I add the little rubber end caps to protect the end of the rod from poking out and hurting someone. They will flex but will not break. Keep them about 1" from each end of the prop. Again to keep it from becoming a stabbing hazard. For a cheaper option, You can find these rods in kite kits. Even at the dollar store places. I found a great way to hold the rod in the center of the object is use thread to suspend it in the middle. Tie one at the top and one at the bottom. Run the thread across the middle of the mold and tie it. It should look like the rod it floating on the threads suspended in space. This way it will not move when the foam expands pushing it to the edge of the part.
I hope this helps and keeps your stunt weapons SAFE above all.

[dewexdewex]

To get a volume for the pour of silicone, just fill the empty mould with rice grains and then tip them out into a measuring cylinder.

[codyc]

I think Norm is doing a great job. While he isn’t the best he represents a lot of viewers who may or may not be educated in these topics. Asking simple questions and explaining certain terms related to the project is extremely easy for me to follow along.

[pauledwards]

Respect the Estwing axe, quality american steel and workmanship and thats coming from a roofer who is in the UK.

[NorthPoleDesign]

Thanks for such a clear overview that answered a lot of questions as I embark on a mold-making & casting adventure!! Sidebar Story: When covid hit, my business of 20 years went straight downhill. Ironic because I design trail maps for Ski Resorts :) So like so many other small businesses, I was essentially shut down. With more time on my hands, I had an idea one night (beers were involved) to carve tikis with a chainsaw - although I'd never used one, sell them locally and use the money to buy lunches for our amazing local Healthcare Workers, Nursing Home staff, homeless shelters, food pantries and other causes of import. My family & I started Tiki Task Force with this crazy idea and it went bananas! Very humbling. At any rate, I'd love to see about creating a mold & casting some of the carvings I've done! This seems like a perfect way to reproduce these pieces, sell them on a bit of a bigger scale and be able to contribute to more & more causes! So thanks again for the insights!

[Tom-zfyl]

Not sure why everyone doesn't like Norm! He just makes sure that the audience knows what is going on, explains things for us. He helped me understand some of the lingo and techniques Frank was using, because for him, its second nature just to do his own thing and not really explain much. Norm is just doing his job, which is hard, because he has to tie the conversation into his questions.

[firefliesburntheworld]

Adam is a busy guy, he can't be in every video. Enjoy the free content you're given. Love seeing Frank work and Norm asks all the right questions that give us all the information we need for the process.

[TofuRabbit]

"Who are you?"
"I am you, but floppier"

[friartuck]

Do more things with Adam, he's the only reason I watch this channel!

[sigilvii]

when I watched this about 5 years ago, I said some negative things about the dynamic between these two. I've been through a lot since then; we've all been through a lot. I just rewatched this video, and YT showed me my comment from 5 years ago. I didn't recognize myself anymore. I didn't like what I had written then. people can change.

you know what? this is a helpful tutorial, and these guys are doing their best to make this information accessible. good job Norm. good job Frank.

[SpaceCadetMotionPictures]

I like what CGI and Green Screen offer, but THIS is the kind of thing that makes me want to make films! Thanks for the very informative video guys!

[GarrisonFall]

Many people are criticising the interviewer (Norm) for asking questions. Maybe you already know all about the subject matter of the videos; I would question then, why are you watching the video?

My experience is that many instructional videos consist of the one person demonstrating how to do whatever it is. Though they MAY be knowledgeable at what they are doing, they too often, don't know about teaching or instructing, so they don't explain what is going on. You'll find their video comments are full of viewers asking questions about aspects that were not properly explained.

Norm asks questions that are very relevant and he seems very good at identifying aspectss that need further explanation or reinforcement. This is very useful for viewers, like me, who want to learn from the videos. Instead of the comments being full of people with unanswered questions, his videos comments are from opinionated 'trolls' who have nothing better to do than mock. That behaviour should have been left behind in primary, or grade school. If you know-it-all, why not make your own videos? At least have the grace to 'keep your mouths shut'.

[ReverendTed]

THIS is the kind of content that keeps me subscribed to Tested. Thanks, guys!

[asyoz]

OMG that axe is an
And it looks like it's a 1950's
And Frank just submerged it in silicone goop.
I'm so pleased the leather handle wasn't affected!
The handle is made of leather strips, layered together, with the tang of the axe going through the middle. The white layers at the front and back of the handle are ivory slices with ebony between them.
Absolutely classical and beautiful.
I would love to have this axe, to go with the matching hammer I have ;)`

[martinj.b.]

The axe's handle isn't wrapped, it's actually a stack of leather discs. You can see how this is done if you look up "How It's Made Axes".

[crazylegsmurphy]

I have never liked this type of mold. I tried it a few times but always resorted back to standard part molds. I find that cutting into the silicone creates too much of a chance of destroying a nice mold, or worse cutting your original piece.

Plus....this way takes a LOT of silicone, which is really hard for anyone working on a budget. It makes more sense to me, to use less silicone (enough to smooth undercuts and such) and back the outside up with a jacket of fibreglass or plaster. That way you use less silicone, and you can be guaranteed your silicone will not warp or bend out of shape.

[leopoldsamsonite]

great video. i really enjoyed that you asked detail questions and pointed out things that were getting glossed over. thank you

[cosprops]

Very cool. Only downside is the cost of using pourable rubber and these foams for this for hobbyists. The finished hammer turned out great.

[cskinner]

Frank is definitely my favorite tested member