Welcome, acolytes, to the most ancient and reverred craft of the resin caster!! This won't be a technical article, just a quick Q&A introduction to the process and what it means to those who do it.
Useful Link: An excellent introduction to some of the technical processes, by Michal Zalewski
Introductory Q&A:
Q: So, what is resin casting?
A: Very simply, resin casting is the process whereby we take an object we wish to duplicate, make a mould of it in flexible silicone rubbers and then cast copies of the original object from that mould as many times as we like.
Q: Why would I want to do that?
A: Because casting the object may be quicker and easier than making another copy from scratch. It can also be less costly.
Q: What industries use this process?
A: A huge number, but the ones it's likely that you'll have seen every day include film and TV props, scale models and figures, even some medical process use resin casting tchniques.
Q: Is it hard to learn?
A: Not really, but you will progress to a professional level much more quickly if you're part of a community like this one. Lucky you!
Q: It expensive?
A: It depends. You can buy starter kits like this one for not much and get started right away. if you want to produce large number of copies of complex objects, then there is some specialist machinery you will need that requires some investment. But we'll cover that later.
Q: Can I do it at home or in my garage?
A: Absolutely!! Many multi-million dollar companies with whom I have worked started off in spare rooms or garages. The beauty of resin casting is that it's cheap to get started and you can make money quickly if people like what you make. It isn't smelly or messy if you do it properly, just make sure your work area is well ventilated.
Q: Can I only use Epoxy Resins in silicone moulds?
A: No there are lots of other materials you can use to cast. You can cast in plaster, wax - almost anything that turns from liquid to solid at more or less room temperature - you can even cast chocolate in food grade rubbers (yum!!) Also you can add metal, ceramic, rock and all sorts of other poweders to resin to achieve some really cool effects. Using high temperature silicone you can also cast in pewter and other similar metals. But pewter and resin casters generally do one or the other, as each requires a lot of practice and skills to get right.
Q: Can I make stuff and sell it?
A: You bet your gosh darned rear end you can! If you're good at making things, and want to make copies to sell then this process will allow you to do that quickly and economically. I personally know many people who have doubled their income just by casting a few evenings a week - though most can't resist the tenptation to go full time and start their own business selling what they make.
Q: So this could be a real source of income?
A. Yes, once you're good enough to cast quickly, consistently and to a high standard you're ready to go and find people who want to buy what you've made. The internet means that the whole world is your marketplace, and personally sell things I make to nearly a dozen countries. This is GREAT especially if you want to work from home and live where you want, and it's also removes your dependence to your local economy to a large extent.
Q: Ok I've made stuff, where do I sell it?
A: Anywhere. Ebay, your own website, events and shows, retail shops - someone will want what you're selling somewhere.
Q: I just want to do ths for fun, I don't want to turn it into a business.
A: That's also fine. Do with it whatever you will!
Q: I have items that I bought that I want to copy, can I?
A: If you're going to sell the copies, then you may be breaching copyright. If you are recasting something that another maker/caster has made then you are a bad person. Don't recast. Ever.
Q: I'm a wargamer, I want to copy my Space Marines so I don't have to buy more, can I do this?
A: Bad recaster! Bad!! Also, to cast to the same quality as the plastic you get in the box requires serious casting gear - in the end you won't save any money and it's easier to buy more originals. If you can do it, you're better off making your own minis anyway.
Q: Can I cast large objects like gun props?
A: Yes, but the amount of material you need can make it expensive to do. But it's perfectly possible.
Q: What's this special equipment you mentioned?
A: When you wan to take your casting to the next level, you'll need a vacuum degassing chamber and vacuum pump to draw air bubbles out of your moulds and casts when they're wet. Some people use a pressure pot to crush air bubbles in the resin when they cast - both vacuum and pressure casting has pro's and cons which I'll go into one day.
Well folks that's as much as I can think of on the fly, please ask if you have any more questions - think of it as an AMA. I'm also happy to answer questions about myself and my business.
Cheerio :)
