Xl Skull, Silicone Mother Mold and Foam Pour - Start to Finish

DIY XL Skull Mold Tutorial | 3D Print to Silicone Mold to Foam Skull
In this full start-to-finish guide, we show you exactly how to turn a 3D printed skull into a silicone mold and pour a hollow foam skull, perfect for Halloween decorations or prop making!

From assembling and sanding a detailed 3D model to applying Smooth-On epoxy, molding with Rebound 25 silicone, and reinforcing with plaster bandage mother molds, you’ll learn all the tips, tricks, and lessons to create a clean, reusable mold.

Whether you’re a cosplay prop maker, Halloween DIY enthusiast, or a fan of foam casting techniques, this tutorial is packed with value:

How to seal voids with foil and clay

Mixing and applying expanding foam

Avoiding air bubbles and mold-lock issues

Repair tips for damaged silicone molds

Materials: Gorilla Glue, XTC-30, Rebound 25, polyurethane foam

The commonly used items that I would highly recommend:
Supplies:
Epoxy for smoothing 3d prints - https://amzn.to/43cLeNb
4 Lb. Density Expanding Pour Foam - https://amzn.to/3O8k41D
6 Lb. Density Expanding Pour Foam - https://amzn.to/3Oo1Md0
Rust-Oleum 255328 Metallic Accents Paint - https://amzn.to/4i4Mqrn
Spray Paint - https://amzn.to/3C9cnp2
Retractable Box Cutter - https://amzn.to/3CuOiJO
Foam Clay - https://amzn.to/4gubHtP
Spray Paint - https://amzn.to/3C9cnp2


Tools:
MINOVA 250W AC Rotatable Electric Hot Knife - https://amzn.to/4fWHzXs
DOMINOX Foam Cutter Hot Wire Cutter Electric Tabletop - https://amzn.to/4i3Iozx
Dremel 4300-5/40 High-Performance Rotary Tool Kit - https://amzn.to/3Zlmtwl
Dremel 2050-15 Stylo - https://amzn.to/4i4y76a
Makita 18V cordless tools - https://amzn.to/3CKY62h
Surebonder Glue Gun - https://amzn.to/4hjMYJ4

Video/Sound:
DJI Mic Mini (2 TX + 1 RX + Charging Case) - https://amzn.to/3V8BE9L
Zoom H6essential - https://amzn.to/495ZaKl
DJI Osmo Mobile 6 - https://amzn.to/4148RH0
Pixel K80 Photography Lighting - https://amzn.to/4fM2rAV

**The links above are affiliate links (Excluding Nova Color). Using the links will help the channel by way of a small commission and is greatly appreciated.


Timestamps:
0:00 - Intro
0:26 – Cleaning up the 3d Model
5:32 – Prepping the Model for Silicone
8:06 – First Layer of Silicone
11:50 - Plaster Bandage Shell
15:16 - Removing the Model
16:42 - Foam Pour
18:05 - Final Thoughts
Let me know in the comments if you tried making this prop and how it turned out! Happy haunting! 🎃💀👻