Consider purchasing a second-hand mixer exclusively for making foam latex puppets.
Foam latex has the ability to produce accurate representations of flesh and muscle when it is cast properly. It also retains its shape, which is important when creating puppets that will be manipulated in either live-action or stop-motion animation. With that being said, foam is extremely difficult to prepare, mold, bake, and set. Jim Henson's "Dark Crystal" characters were created without molds. He applied wet latex foam to a pre-carved polyurethane foam. This is a slightly simpler process since the mold making and long curing time can be skipped.
Instructions
1. Create your molds. Typically you will need two to five pieces, the front and the back, and then any additional elements such as hands, a tail or wings will also need a two-piece mold. Molds can be made from gypsum, fiberglass, epoxy, or flexible silicone. Be sure the mold is bone dry before using; this can take several days.
2. Connect the two halves of each part of the mold. Connect with purchased belt clamps. Drill holes in the mold in order to add the latex foam. Have your mold complete before mixing the latex foam.
3. Mix the foam formula according to the manufacturer's instruction. Foam kits and extra supplies can be purchased online. Burman, a leader in the special-effects field, offers several sizes of foam latex kits. The Monster Makers and Kryolan are other companies selling foam latex kits online.
Before mixing, put on your protective gear; apron, gloves, eye protection, and face mask to protect yourself from the chemicals. You will need to measure the latex, foaming, and curing agent into a paper cup, and stir with a mixing stick. Measure and place gelling agent in separate cup.
Use a free standing mixer with a whisk attachment that is dedicated to puppet making. Once used to create latex foam it should not be used for food. Froth the latex mixture closely following all the steps outlined in the manufacturer's directions.
4. Pour the mixed foam into a special foam injection gun. A small foam injection gun can be purchased from an online special effect supply company. Inject the foam into the mold. This needs to be done quickly since the foam can set up inside the gun making it impossible to get through the nozzle.
5. Place the mold in an oven or kiln. Set the temperature according to the instructions of your particular foam manufacturer. Be sure the oven temperature is accurate. Use a separate temperature gauge if necessary. If you are using a regular home kitchen oven, place the molds in heat proof plastic bags; the kind made for cooking poultry. After baking the foam, thoroughly clean oven.
6. Use oven gloves to remove the molds from the oven. Cool the molds at room temperature for several hours, or overnight. Carefully remove the clamps and add detailing with paint, fabric, and other trim.
7. Latex foam can also be colored with fabric dyes once the puppet has cured. Another way of coloring the puppet is to spray on a mixture of 1 part acrylic paint, 4 parts latex, and 5 parts ammonia water.
8. Glue parts together or add items to the foam latex puppet with contact cement. It is available in home improvement, art, and craft stores.
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