Prop Making
A wide variety of effects and objects can be created using Polytek® materials, including faux glass objects, breakaway glass (PlatSil® SiliGlass), faux bronze objects, lightweight foam props, life-like silicone props, safe weapon props, historical object reproduction, scenery and much more.
Once an original design is created by an artist, a flexible polyurethane or silicone mold or rigid plastic mold can be made of the original. A variety of materials can then be cast in the finished mold, including plastics, foams, polyurethane and silicone casting rubbers, plaster, concrete and more.
In some cases, foam carvings are hard-coated with a fire-rated plastic shell to provide a durable outer coating which can be easily painted.
View popular product options below:
Use Polytek® polyurethane casting resins to create a variety of props.
Select an option below for more detailed product information or browse all polyurethane casting plastics.
| Product | Description |
|---|---|
A fast-setting, low-viscosity white plastic that can be used to make a variety of rigid props. Easily accepts fillers like Bronze Powder and be colored with PolyColor Dyes. |
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A translucent, amber version of EasyFlo 60. Color with PolyColor Dyes for colored, translucent castings. |
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| EasyFlo Black Liquid Plastic | Cures to a deep, black color without the addition of PolyColor Dyes. |
A fast-setting plastic often used for slush-casting or rotational casting to produce lightweight, hollow castings. |
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A fast-setting, UL-94 (V-0) fire-retardant polyurethane plastic. |
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Water-clear plastics that can be used to make faux glass objects and other objects where optical clarity is a must. Can also be colored with PolyColor Dyes. |
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A slightly flexible plastic that is sometimes used for props that require a hard plastic that bends slightly. |
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A low-density (floats in water) rigid plastic for making lightweight props. |
Polyurethane and silicone foams are often used to produce lightweight props and décor. They can be used to make finished parts, but are also used to backfill other casting materials, such as polyurethane plastic, polyurethane rubber and silicone rubber.
Select an option below for additional product details and buying information:
Rigid PolyFoams
Three rigid polyurethane foams at varying free-rise densities: 2.5, 5, and 8 lb/ft³.
Product |
Mix Ratio |
Free-Rise Density |
Molded Density |
|---|---|---|---|
1A:1B |
2.5 lb/ft³ |
4-8 lb/ft³ |
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1A:1B |
5 lb/ft³ |
8-20 lb/ft³ |
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1A:1B |
8 lb/ft³ |
8-20 lb/ft³ |
Flexible PolyFoams
Two flexible polyurethane product options at varying free-rise densities: 3 and 5 lb/ft³.
Product |
Mix Ratio |
Free-Rise Density |
Molded Density |
|---|---|---|---|
1A:2B |
3 lb/ft³ |
5-8 lb/ft³ |
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1A:1B |
5 lb/ft³ |
8-15 lb/ft³ |
PlatSil® SiliFoam Casting Foam
A platinum-cured silicone foam with a free-rise density of 15 lb/ft³. Most often used to backfill PlatSil® Gels to make life-like silicone props.
Product |
Mix Ratio |
Free-Rise Density |
Molded Density |
|---|---|---|---|
1A:1B |
15 lb/ft³ |
15 lb/ft³ |
All Polytek® polyurethane rubbers can be cast into compatible molds, but PT Flex Series Casting Rubbers are very popular because of their low-viscosity mixes, simple 1A:1B mix ratios and fast demold times.
Select the product line below for more detailed product information or browse all polyurethane rubbers.
| Product Line | Description |
|---|---|
Fast-setting rubbers for quick turn-around. Available in several hardness levels. |
The following two products are specialty silicone products that are used often in prop making and special effects. All other Polytek® silicones can also be cast to create props and parts.
Select an option below for more detailed product information or browse all silicone rubbers:
| Product | Description |
|---|---|
A platinum-cured silicone designed for making super-clear, glass-like rubber castings for special effects and prop applications. SiliGlass is designed to act and look like broken glass when hit. |
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PlatSil® Gels are widely used in the special effects industry for creating life-like theatrical prosthetic appliances, as well as for lifecasting, prop making and general silicone mold making. These versatile silicones are contact-safe, fast-setting and offer easy 1A:1B mix ratios by weight or volume. |
A NOTE ON CURE INHIBITION: Sulfur-containing clay and other sulfur/tin/amine-contaminated materials and tools will cause cure inhibition in platinum-cured silicone rubbers, which means that the rubber that is in contact with the contaminated material or surface will remain gummy or uncured. Make sure to test cure the rubber on your surface before full-scale application.
Hardcoat foam carvings with a plastic shell to provide a durable outer coating which can be easily painted.
Select an option below for more additional product information:
| Product | Description |
|---|---|
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A fast-setting sprayable polyurethane system to hardcoat rigid surfaces such as hotwire-cut EPS foam, MDF or wood. This thin, tough and easy-to-sand coating can be applied in one or more layers. This is a flame-retardant product: UL-94 (V-0). This plastic can be sprayed with a PlakPak Spray Gun. |
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EasyFlo Series Liquid Plastics & PolyFiber II |
For a fast-setting, brush-on hardcoat, add PolyFiber II thickener to EasyFlo-Series Liquid Plastics to bring these low-viscosity resins to a brushable consistency. Use EasyFlo 60 or EasyFlo 95 (a slower-setting version) plastics. |
Polytek® silicone mold rubbers are most often used when making molds for resin or foam casting - release agents are generally not needed for either process, which is why they are sometimes preferred over polyurethane mold rubbers. For resin castings that need to be painted after casting, silicone mold rubbers are recommended. Tin-cured and platinum-cured silicone options are both available.
Select an option below to browse silicone rubbers:
Rubber Type |
Advantages |
Disadvantages |
Casting Materials |
Methods |
|---|---|---|---|---|
No shrink on cure, cured rubber has long storage life, high strength, excellent chemical resistance. |
Liquid rubber can suffer from cure inhibition from some materials (e.g., sulfur clay, tin silicones, Bondo, some 3D-printed plastics, latex rubber). |
Most materials, especially resins, foams and some low-melt metals. |
Pour, Brush, Spray. |
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High strength, excellent chemical resistance, slightly less expensive than platinum-cured systems. |
Shrinks on cure (~1%), shorter library life (2-5 years total) than platinum-cured systems. |
Most materials, especially resins, foams and some low-melt metals. Can inhibit polyurethane rubber, platinum-cured silicone, and 14-Series Poly-Optic Resin castings. |
Pour, Brush, Spray. |
A NOTE ON CURE INHIBITION: Sulfur-containing clay and other sulfur/tin/amine-contaminated materials and tools will cause cure inhibition in platinum-cured silicone rubbers, which means that the rubber that is in contact with the clay model or contaminated surface will remain gummy or uncured. Make sure to test cure the rubber on your surface before full-scale application. Use a polyurethane or tin-cured silicone rubber if you know that you’ll be working with any of these inhibitors.
Polytek® polyurethane mold rubbers are most often used for casting wax, plaster and concrete. Release agent is generally not required when casting wax and plaster, but is needed when casting concrete. Resin casting can also be done in polyurethane molds with an appropriate release agent. Polyurethane molds are economical (less expensive than silicone mold rubbers) and long-lasting.
Select a product series below for individual product information or browse all polyurethane rubbers:
| Product Line | Description |
|---|---|
Soft to Medium Hardness Rubbers. High-strength, abrasion resistant, longest-lasting rubbers. Economical & versatile. Shore Hardness Range: A20 to A55. |
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Medium to Hard Rubbers. High-strength, abrasion-resistant, super-tough rubbers. Long lasting & economical. Shore Hardness Range: A60 to A80. |
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Fast-Setting Rubbers. Fast-setting, rapid demold polyurethane rubbers. Shore hardness Range: A20 to D60. |
Thin, brush-on or spray-on molds require a supportive mold shell. Mold shells can be made with a number of materials, including plaster, polyester resin and fiberglass and thickened polyurethane plastic. Polytek® offers strong, fast-setting polyurethane plastics that are widely used in mold shell construction.
Select an option below for additional production details:
| Product | Description |
|---|---|
A polyurethane casting plastic with a 5-minute working time. Thicken with PolyFiber II for brush-on application. |
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A polyurethane casting plastic with slightly longer working time (10 minutes) than Poly 1512X. Thicken with PolyFiber II for brush-on application. |
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