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Molding & Casting
A set of molds are made of the full-sized sculpture. The molds are made from an epoxy that is very durable and has strong bonding characteristics.
Once the components of the animatronic are ready, much of the frame work is test fitted inside the molds before the foam rubber skin is cast. In conjunction with this step is the fabrication of the foam-running core, which is created by lining the inside of the mold with precise layers of clay to represent the skin thickness. When the clay lay-up is completed, the surface of the clay is fiberglassed to create the foam-running core. After the clay is cleaned out, the foam-running core is bolted into the mold and creates a negative space between the foam-running core and detailed surface of the mold. When filled with foam rubber, this negative space becomes the skin.