Sofia Martinez
Casting a doll with plastic involves a multi-step process that blends sculpting, molding, and casting techniques. The process begins with designing the doll, sculpting it out of clay, and baking it. After cooling and sanding, a two-part mold is created for the body and head using silicone RTV rubber. This mold captures the shape and details of the clay doll, including the neck hole for attaching the head. The mold is then used to cast the doll in plastic resin, specifically polyurethane resin, which gives the doll a porcelain-like finish. The resin is mixed, tinted to the desired colour, and poured into the mold. Once cured, the doll pieces are removed, sanded, and painted. This intricate process allows hobbyists to create professional-grade plastic dolls with customisable features and colours.
| Characteristics | Values |
|---|---|
| Materials | Super Sculpey clay, silicone RTV rubber, catalyst, resin, latex gloves, safety goggles, vapor respirator, acetone, cotton pads, q-tips, polyurethane resin, urethane resin, resin dye, Styrofoam, plastic wrap, masking tape, aluminum foil, paper clay, straws, wooden craft balls, Legos, cardboard, baking sheet |
| Tools | Oven, razor blade, rubber bands, dremel or craft blade |
| Process | Draw an in-scale design for the doll, including a method for attaching the head to the neck (e.g., a hole in the base of the head and a rounded ball on the neck). Create a two-part mold for the body and head using a combination of materials. Mix and pour resin into the molds, then let cure before removing the pieces and assembling the doll. Sculpt, sand, and paint as desired. |
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What You'll Learn
Sculpting the doll from clay
First, create a basic structure for your doll using foil or Styrofoam. This will serve as the armature, providing a base for the clay to be applied. Wrap the foil or Styrofoam with masking tape to hold it together. You can also use straws for the arms and legs to provide support.
Once you have the basic structure, start covering it with clay. Super Sculpey clay or polymer clay is commonly used for this purpose. Smoothly apply the clay over the entire structure, ensuring you achieve the desired thickness for sculpting. Remember to leave a slight gap between the core and your anatomical sketch, about 2 to 5 mm.
Now, you can begin sculpting the doll's features. Use your hands or sculpting tools to shape the clay, adding details such as the face, hands, and feet. Remember to add rough hip and shoulder sockets to the torso. You can also add balls to the tops of the lower arms and legs, covering them with plastic wrap, and then add clay to the bottoms of the upper arms and thighs to create sockets for movement.
After sculpting the main body, focus on the head. Carve out the basic shape of the head, making sure to include a design element for attaching the head to the neck. This usually involves creating a hole in the base of the head that will fit snugly onto a rounded ball at the end of the neck. You can also add details like hair and facial features, such as drawn-on eyebrows, lashes, and eyes, especially if you're creating a smaller doll.
Once you're satisfied with the sculpting, it's time to bake the clay doll in the oven. Follow the packaging instructions for temperature and timing. After baking, let the doll cool completely before proceeding to the next step.
Finally, sand down the clay to smooth out any rough surfaces and refine the overall appearance of your clay doll. This step will help create a seamless finish before you move on to the moulding and casting stages of the plastic doll-making process.
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Creating a two-part mould
To create a two-part mould for a doll, you will first need to sculpt the doll out of clay, bake it, and let it cool. You can then create a two-part mould for the body and head.
For the body, build a wall around the clay doll using Lego blocks or cardboard, leaving a 1/4-inch clearance on all sides and top and bottom. Use a sheet of modelling clay for the base. Mix a batch of silicone RTV rubber and catalyst, following the packaging instructions. Fill half of the mould box with the rubber mixture and press the doll body into it so that the bottom half is covered. Press wooden craft balls into the rubber around the body, then let it cure overnight.
Remove the craft balls and mix another batch of rubber. Pour this on top of the cured rubber, covering the doll body completely. Let this cure overnight as well. Separate the mould halves and remove the doll body.
Repeat the process for the head, making sure to include an indentation for the neck hole. Carve a pouring hole into each mould half with a razor blade. Fit the mould halves together with rubber bands.
You are now ready to cast your mould. Mix a batch of resin and catalyst, following the packaging instructions. Pour the resin into each mould until they are filled. Let them cure for a day, then separate the mould halves and remove the doll pieces.
It is recommended to wear latex gloves, safety goggles, and a vapour respirator when working with resin, as well as working in a well-ventilated room.
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Casting the doll
Once you are happy with the shape and details of your doll, bake it in the oven according to the clay packaging instructions. Allow it to cool completely, then sand it down to achieve a smooth finish.
The next step is to create a two-part mould for the body and head. Build a wall around your doll form with Lego blocks or cardboard, leaving a 1/4 inch clearance on all sides and the bottom. Use a sheet of modelling clay for the base. Mix silicone RTV rubber and a catalyst, following the package instructions, and pour it into the mould box, covering the bottom half of the doll. Press wooden craft balls into the rubber, then let it cure overnight. Remove the craft balls and pour in more rubber to cover the doll completely. Allow this to cure, then separate the mould and remove the doll.
Now you have a mould, you can cast your doll with urethane resin, purchased from a casting supply store. Tint the resin with dye to your desired skin tone or colour. Fit the mould halves together with rubber bands, then pour in the resin. Allow the resin to cure, then de-mould the pieces.
Finally, sand the pieces if necessary and paint them with acrylics. Assemble the head and body, and your doll is complete!
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Demoulding and curing
Demoulding:
Firstly, let the rubber cure overnight. It is important to be patient during this step, as insufficient curing time can impact the final result. Once the curing process is complete, carefully separate the mold halves and remove the doll body. Repeat the process for the head, creating a two-part mold. This two-part mold technique ensures that you can capture the intricate details of the doll's head and body, including the neck hole, which is essential for attaching the head to the body later.
Curing:
After demoulding, it's time to cure the resin. Mix a batch of resin and catalyst, carefully following the packaging instructions. Wear latex gloves, safety goggles, and a vapor respirator during this process, and ensure the room is well-ventilated. Carefully pour the resin into each mold, filling them completely. Allow the resin to cure for a full day. The curing time may vary depending on the specific resin and catalyst mixture used, so always refer to the manufacturer's instructions.
Final Demoulding:
After the curing process is complete, carefully take the mold halves apart and gently pull out the doll pieces, taking care not to damage the cured resin. Inspect the pieces to ensure they have cured properly and taken on the shape of the mold. If desired, you can sand the pieces to achieve a smoother surface and add acrylic paint to customise the appearance. Finally, attach the head to the body, securing it in place using the neck hole.
Safety Precautions:
When working with resin, it is crucial to prioritise your safety. Always wear the appropriate personal protective equipment, including gloves, goggles, and a respirator. Resin dust can be toxic, so when sanding resin, consider doing so underwater or while wearing a particle respirator. Ensure the work area is well-ventilated to avoid inhaling resin fumes.
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Painting the doll
Once you've cast your doll, it's time to paint! Here are some detailed instructions to guide you through the process of painting your plastic doll:
Preparing the Doll's Surface:
Before you start painting, ensure the doll's surface is smooth and free of any imperfections. You might need to sand the pieces lightly, especially if you want to achieve a seamless finish. After sanding, wipe down the doll with a soft cloth to remove any dust or particles.
Choosing the Right Paint:
For plastic dolls, acrylic paints are a great option. They adhere well to the plastic surface and are available in a wide range of colors. You can also use watercolor pencils or pastels, but make sure to use a suitable sealant beforehand to ensure better adhesion.
Sealants:
Using a sealant is crucial when painting plastic dolls. It provides a tooth-like surface for the paint to cling to and helps prevent the paint from rubbing off during play. Mr. Super Clear is a popular choice, but be warned: it's highly toxic and has a strong odor. Always work in a well-ventilated area when using sealants and paints.
Start with the face, as it requires more detail and precision. Use thin layers of paint, building up color gradually. For the eyes, prevent the paint from dulling the glossy plastic by covering them with Scotch tape before painting. You can add sparkle to the eyelids using PearlEx powder, a craft product that adds a beautiful glittery effect. Mix this powder with acrylic paint to create a metallic finish, perfect for a ballgown or fairy-themed doll.
For the body, consider the type of plastic. Hard plastic bodies, like those of Disney Princess dolls, Barbies, and Bratz, take paint well. Softer, rubbery plastics are less suitable for painting, especially around the joints where the paint can easily rub off.
Finishing Touches:
After you've finished painting and allowed the paint to dry, you might want to add a final coat of sealant to protect your artwork. You can also use varnish to add shine to certain areas, such as the lips, for a glossier look.
Remember, when painting your doll, take your time, and don't be afraid to add thin layers of sealant between paint layers to ensure your artwork lasts.
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Frequently asked questions
You will need clay, tinfoil, silicone RTV rubber, a catalyst, resin, latex gloves, safety goggles, a vapor respirator, and paint.
First, sculpt the doll out of clay and tin foil. Then, create a two-part mould for the body and head out of silicone RTV rubber. Next, pour resin into the moulds and let them cure. Finally, sand the pieces and paint them as desired.
Polyurethane resin is a type of plastic with a porcelain-like finish. You can purchase it from a casting supply store and tint it to your desired colour using resin dye.
When working with resin, it is important to wear latex gloves, safety goggles, and a vapor respirator. You should also work in a well-ventilated room to avoid inhaling fumes.
