I decided to create my main puppet for my Klimt-inspired stop motion short "Falling" out of a material called foam latex, which is poured into a mold over a wire armature. Since this was my first time fabricating with this process, I was really lucky that
Justin Connolly was doing a workshop at USC on mold making and agreed to use my clay sculpt of my puppet as an example.
Here is a photo of how his mold came out. He made it by laying down the clay body (Sculpey) and building up walls around it with water-based clay. This created the negative shape for the mold, and we mixed a type of cement called Ultracal which is the material you are seeing in this photo. If you use Ultracal be sure to be in a ventilated space.
Check out Justin's blog for
more info on this process.
After Justin helped me through making the mold of the body, I repeated the same process to create a mold for the puppet's head. I sculpted it and used beads to create the concave space where the eyeballs would be.
Pretty creepy-looking, huh? I kept the mouth open to allow for an animatable jaw armature.The Ultracal bonded with the beads so that they became a part of the mold. You can see the remains of my clay sculpts. If you ever make molds this way be prepared for them to be useless afterwards.
The next step was to build my armature.
Lastly, I lucked out again in my foam puppet-making adventure because I was helping out on the fabrication end of a short stop motion film being made by Shel and Justin Rasch called
The Line, and Shel took an entire afternoon to help me improve my armature, teach me how to mix the latex (much like making cake) and how to pour it. Then she let me bake it in her oven for several hours until the foam had set.
It's important to remember not to use an oven you actually eat from when baking any stop motion materials like foam latex or sculpey clay.
I found this method of puppet making really meticulous and time-consuming, but in the end it really paid off because I was able to get the texture I wanted without having to deal with the fickleness of clay.