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Vacuum Forming

These clips all demonstrate the vacuum forming process. This is how we make our armor!

The first is a carefully edited clip, as shown at the Star Wars Celebration 5 animated costuming panel.

The next two are just rough footage taken with an iPhone.

Molding a Helmet

This video shows you how we made a mold of our Deathwatch Mandalorian helmet. There are several of us working on these outfits for Celebration 5, so it made sense to do it this way, rather than scratch building them all. I get more questions about this than anything else. Please, please, please read this before asking something!

  • Please do not send me a message asking where to get the materials, how much they cost, etc... Seriously, if all the big blue and yellow buckets with Smooth-On labels aren't a dead giveaway, you aren't ready for this sort of project. (Hint: try
  • A sample size container of Rebound 25/Plasti-paste is not enough. Two sample size containers isn't enough either. You'll notice in the video I have gallon containers. This is not a coincidence! Yes, it costs around $300 to make a mold. Really.
  • This video is about make a mold of a helmet, not casting a helmet. For information on casting a hollow object, look up slush casting on Google or YouTube.

Slush Casting

The next common question is how to make a hollow helmet. This is usually called rotational casting, rotocasting or slush casting. We typically use Smooth-On's smoothcast 65D resin here, with Urefil 3 filler. About 32 ounces of resin goes into a helmet, plus 12 ounces of Urefil.


I get a lot of questions about how I do my weathering. It's hard to explain, so I made this little video clip of the process. It's not the greatest in the world... it was filmed with an iPhone. But it gets the idea across and was fun to do.

This one is a lot better. It's a time lapse video of me weathering a Rex helmet. And to answer another frequent question / comment: The lines on Rex's helmet are supposed to be jagged and uneven. This is not bleed from the tape. This is tape that was torn lengthwise to intentionally leave a rough edge.

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