Total beginner asks: How do I cast latex masks from a 3D print?
TL;DR: how do I make slip-cast latex reproductions of a rigid object?
The long version:
I'm tasked with making several dozen latex monster masks for a volunteer project, and I'm a bit stumped on how to go about it.
Disclaimer: I have no clay-modeling experience and have never worked with latex or silicone before. BUT, I am a pretty decent 3D modeler/sculptor, and I've got a lot of 3D printing experience.
I've made a 3D model of the mask I want to reproduce, and a large format 3D printer. As I don't have any clay modelling experience, my plan was to 3D print this mask, sand and prepare it to get rid of the layer lines, and then pour a plaster negative of it. Then I'd use that mold to slush cast the latex masks.
My problem: how on earth would I get the 3D print out of the plaster? Generally folks use clay, and then just scoop/melt the clay out of the plaster so it leaves the negative. Can't really do that with a rigid 3D print. Obviously my first thought was to just make the mold out of silicone instead of plaster, but apparently latex basically never cures in a silicone mold?
The best I've come up with is what seems like a pretty laborious multi-stage process of first making a silicone version of the mask so that I can actually remove it from the plaster mold. I don't even know whether it's possible to cast silicone in a silicone mold.
Either that, or I try to convince the folks I'm doing this for to pay 2-3x more for materials and just do the masks in silicone. Unfortunately cost is king (this being a fully volunteer organization) so I don't think that'll fly.
Anybody here know a better way to go about doing this?