How to Use Castable Materials to Create Cosplay Props

Post by guest contributor Brooke Chaplan.

A fierce cosplayer is wielding a massive, expertly-crafted battleaxe. Photograph via Unsplash.

Being able to create your own props gives you greater flexibility when it comes to controlling the design of your cosplay. Doing it at home also works to reduce the price and leaves you with more room in your budget. Here are just a few of the ways that you can go about using castable materials in your props for cosplay.

Fiberglass Options

Fiberglass has always been a popular option in that it can lend you rigidity or even be used as a base for something more life-like. There are a variety of options when it comes to the use of fiberglass. The resin can be colored to be more realistic, and fiberglass also allows you to paint your material to suit your needs. The use of vacuum sealing is common with fiberglass because you can mold it into the shape that you need to be a base for any type of prop.

Versatile Plastics

Plastics still reign supreme when it comes to creating your own line of cosplay props. This is because it’s easier to work with the materials at a lower temperature to achieve the desired results. A Polyurethane casting material supplier may able to help you locate the plastic castable materials that you need to craft your realistic items. Make sure to use a mold that has been treated so that you can easily remove your prop.

Wax Molds

The use of wax molds is fairly common when you’re working with metals. This is because the wax will melt and leave you with the perfect cosplay prop. You’ll need to encase your mold into something like sand so that the metal will have a chance to cool before the mold is destroyed. Consider using a lower melting point material so that it will cool at a faster rate and stay intact throughout the process. It will also make it easier for the DIY enthusiast.

Silicon and Rubber Materials

Silicon and rubber molds and materials are popular for many different reasons. The mold itself is great because it has many of the nonstick qualities that you require when you’re creating your props. The material is also good because it gives you a greater range in terms of the items that you’ll be able to create. This is due to the flexible nature of the material. It’s easy to paint or even shave down to the dimensions that you want.
You have loads of options when it comes to finding the right castable material for your cosplay items. Use these solutions when it comes to making something that will appear realistic and be easy to manage.


Brooke Chaplan is a freelance writer and blogger. She lives and works out of her home in Los Lunas, New Mexico. She loves the outdoors and spends most of her time hiking, biking, and gardening. For more information, contact Brooke via Facebook at facebook.com/brooke.chaplan or Twitter @BrookeChaplan

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