To: <puptcrit-AT-puptcrit.org>
Date: Tue, 9 Sep 2008 18:19:41 -0400
Subject: [Puptcrit] Paper Casting for puppets



I've successfully cast an intricate detailed sculpt with some strong paper 
pulp.
After a few tests with various papers, I went with a classic: 100% cotton 
linter and water, squished into the plaster mold with a sponge to remove 
most mositure. The linter was a single sheet of 100% cotton paper I turned 
to pulp by soaking and beating with a plaster attachment for the drill)

I sped dried it in the oven at 200F, but only turning the oven on for a few 
minutes at a time, leaving the piece in the remaining heat. No discernible 
warping, and the flash line (two part mold) is going to be easy to trim, so 
I'm very happy!

The mold, being very freshly made (3 days) suffered two small breaks of 
inside detail, but I'll easily repair them to make the copy I'll keep for 
myself. It was unavoidable, I had no time to wait any longer for the mold to 
dry.
The cast itself was not noticeably affected by the break.


I intend to make puppet parts using this process. I once was sent a jar of 
Li-Qua-Che (liquid paper mache) by a customer so I could test it for use on 
an upcoming project. The casting was easy to do, the detail level was 
amazing, but the result was insanely brittle. Cotton linter is more than a 
bit more work, especially when trying to reach into very small and deep 
details with a sponge, but it gives a great definition and enough strength 
to build upon.

The detail level is ideal, and the strenght is sufficient, for the surface 
will be hardened during the sealing stage.
The insides will be made stronger with sealer, then paper strips.

For this project, which is a working doorknocker, it will also have the 
knocking part and some door fixture harwdare inside, so the rest will be 
filled with expansible foam (i got a can of "Great Stuff", will allow for 
the extra expansion to exit from the back, then cut it to size).

Can't post pics yet, I don't want to spoil it for my friends who shall 
receive it as a wedding gift this week-end.
Pics (including WIP and some pics of the medieval costume) coming after the 
medieval week-end...
Gotta go back to work, I still have to finish the costume, and make another 
gift from scratch!






 

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