EVA Foam molding and casting?? Need Help.

[Novocaine127]

I'm in a large home film production and i am in charge of constructing the prototype helmet for the troopers. I need to know if it is possible to Make a mold of a helmet constructed completely out of EVA foam? We need to cast a bunch of these. If not by itself, is there something i could coat the foam in that would make it possible to mold and cast it? Thanks in advance for the hopefully speedy reply! -Tanner

 

[FlyinPhil]

Hey Tanner. First off, a pepakura helmet will give better results for detail and reproduceability, as any imperfections in a foam helmet will carry into each cast.

That being said, a few very light layers of wood glue will give the foam a hard and smooth, though fragile, shell. That should allow you to make a decent cast!