Please note: I get quite a few e-mails from folks that want to make their own toys. I have trouble keeping up with the volume of e-mails on this subject, so please understand if I can’t write back with specifics. This is a quick outline to let people who are interested in my process to know generally how it works. Some of these images are a bit dated, but my general process has been the same since about 2007. Youtube has some great tutorials on mold making and is a good place to start if you’re interested in casting in resin.
Most of my resins start off as a very crude sketch so I can develop a general idea for the character. Next I make a wire and foil armature to determine the scale and proportion of the character. This is the framework I use to sculpt upon with polymer clay. Once the sculpt is finished, it is cured so it’s firm. Then I start a cycle of sanding and priming until the prototype is complete.
Next I place the prototype in a box which is then filled with liquid silicone that forms the mold. Once the mold is set, I make duplicates of the original prototype by pouring polyurethane resin into the mold cavity which sets into a rigid plastic. After sanding the casting, I paint each piece by hand after it comes out of the mold.
The whole process often takes between 2 and 6 weeks, depending on the size and complexity of the character.