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| Production molds are originated from the same “master”, which is the approved and signed off first helmet. Using the "original" means we can maintain quality and accuracy. For production, a series of silicone molds are poured around the master helmet. These are then jacketed by an outer fiberglass case to ensure the molds maintain the integrity of the helmet's shape. The detail, i.e. the surface of the helmet, "exists" only in the silicone inner skin. Silicone is an ideal material as it retains surface detail extremely well and doesn't adhere to the casting materials. A series of gel coats (a polyester resin mix) and fiberglass matting are laid and painted by hand into the molds and allowed to cure. When they have set, the outer jackets and the silicone molds are removed revealing a series of clone trooper helmets exactly as if they had come off a Kaminoan production line. Some of the pictures show a thin layer of gel coat where the visor will be. This resin is removed and a smoked black visor is added during a later stage of assembly. The excess molding material around the neck collar is also carefully removed and any imperfections in the castings are addressed at this point. |
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