Digital Models, Printed Molds & Practical FX Fabrication

2-Day Live Online Workshop | 4 Hours Per Day | 8 Hours Total

Course Details

Format: Live Online Workshop
Duration: 2 Days / 4 Hours Per Day
Total Instruction: 8 Hours
Experience Level: Beginner to Intermediate
Focus: Resin 3D Printing, Makeup FX, Prosthetics, Mold Making & Props
Designed For: Makeup FX Artists, Prosthetic Artists, Mold Makers, Creature Artists, Prop Makers & Practical Effects Fabricators

Live Online Training via Zoom

This course will be taught live online through Zoom, allowing students to participate from anywhere.

Learn how to bring digital 3D models into the real-world workflows of professional makeup effects, prosthetics, mold making, creature fabrication, lifecasting and prop building. This intensive two-day online workshop covers the complete resin 3D printing process, from preparing and repairing digital files through slicing, printer setup, supports, troubleshooting, post-processing, finishing and creating 3D printed molds.

Designed specifically for makeup FX artists, prosthetic artists, mold makers and prop builders, the course focuses on how resin 3D printing can become part of a practical FX shop workflow. Because the workshop is taught live online, you can participate from anywhere. Follow along step-by-step on your own tablet or computer, or simply watch the demonstrations and take notes. Each session also includes a live interactive Q&A with instructor Dallas Harvey.

Day 1: Digital Model to Resin 3D Print

• Understanding 3D models, meshes, polygons and resolution

• STL, OBJ and common 3D print file formats

• Working with downloaded and pre-made 3D models

• Preparing original Nomad Sculpt, ZBrush and scanned models

• Preparing 3D scans and lifecast scans for printing

• Cleaning and repairing damaged geometry

• Checking watertight and printable geometry

• Scaling models accurately

• Wall thickness, tolerances and mechanical fit

• Hollowing models and adding drainage holes

• Dividing larger models into printable sections

• Creating registration systems for multi-part prints

• Designing specifically for resin 3D printing

• Understanding slicing software

• Layer height and print resolution

• Print orientation

• Automatic vs. manual supports

• Light, medium and heavy supports

• Recognizing unsupported islands

• Reducing support marks on important surfaces

• Resin printer setup and calibration

• Build plate preparation and leveling

• Resin vats and release films

• Exposure settings

• Choosing resin for FX applications

• Standard, tough, flexible and high-detail resins

• Preparing and starting a resin print

• Estimating print time and resin usage

• Diagnosing failed prints

• Troubleshooting support, adhesion, warping and separation problems
  

Day 2: Post-Processing, Finishing & Printed Molds

• Safely removing resin prints from the printer

• Protecting the build plate and finished print

• Removing supports without damaging detail

• Heat-assisted support removal

• Cleaning support contact points

• Washing and cleaning resin prints

• Cleaning hollow prints and internal cavities

• Drainage and trapped resin

• Drying prints before curing

• UV curing

• Proper cure times

• Avoiding under-curing and over-curing

• Identifying print defects and surface problems

• Repairing holes, seams and damaged details

• UV resin repair

• Epoxy, fillers and spot putty

• Joining multi-part resin prints

• Blending seams

• Reconstructing missing details

• Sanding resin prints

• Removing layer lines and support marks

• Progressive surface refinement

• Priming and surface preparation

• Sealing prints for mold making

• Preparing prints for silicone, plaster, Ultracal, epoxy and polyurethane

• Mold release and surface compatibility

• Preventing silicone inhibition

• Painting and airbrushing finished prints

• Weathering and surface detailing

• Matte, satin and gloss finishes

3D Printed Mold Design for Makeup FX

Learn how resin 3D printing can be used to create professional molds and mold components for prosthetic makeup and practical FX fabrication.

• Understanding positive and negative mold geometry

• Mold walls

• Cutting edges

• Bleed areas and flashing

• Registration keys

• Pour points and air vents

• Mold thickness and strength

• Designing molds for casting materials

• Creating a one-part mold in Nomad Sculpt

• Preparing the digital sculpture

• Creating the mold block

• Boolean subtraction

• Creating the negative mold cavity

• Cleaning Boolean geometry

• Adding mold walls and registration details

• Creating a two-part mold in Nomad Sculpt

• Determining the parting line

• Dividing the mold

• Positive and negative registration keys

• Bolt holes and mechanical registration

• Pour spouts and air vents

• Testing mold alignment

• Exporting individual mold sections for printing

Prosthetic Mold Applications

• Flat molds

• Silicone prosthetic molds

• Two-part compression molds

• Encapsulated silicone prosthetic molds

• Cutting-edge design

• Overflow channels

• Injection and pour points

• Registration systems

FX & Prop Applications

Learn how resin 3D printing can be incorporated into workflows for:

• Prosthetic makeup molds

• Silicone prosthetics

• Lifecast positives

• Head and face forms

• Prosthetic sculpture bases

• Creature sculptures

• Creature components

• Anatomy props

• Body duplication

• Dental FX components

• Puppet parts

• Armatures and small mechanical components

• Mold components

• Small props

• Production prototypes

• Custom FX tools and fabrication components

Digital-to-Practical FX Workflows

Explore how digital tools and resin printing can integrate with traditional practical effects techniques:

3D Scan → Digital Sculpt → Resin Printed Positive → Traditional Mold

3D Scan → Digital Sculpt → Digital Mold → Resin Printed Mold → Silicone Prosthetic

Digital Creature Design → Resin Print → Mold → Silicone Casting

Lifecast Scan → Digital Cleanup → Resin Print → Prosthetic Sculpture Base

Additional Topics

• Choosing your first resin 3D printer

• Choosing an appropriate printer size for FX work

• Selecting resin for molds, props and FX fabrication

• Essential printer tools and accessories

• Resin storage

• Printer maintenance

• Replacing release films

• Build plate maintenance

• Safe resin handling

• Ventilation and PPE

• Disposal of resin and contaminated materials

• Organizing digital print files

• Archiving production assets

• Estimating resin cost

• Estimating material usage

• Calculating print time

• When 3D printing is faster than traditional fabrication

• When traditional fabrication is still the better choice
  

Learn Your Way: Follow Along or Just Watch

This live online workshop is designed to work with different learning styles.

• Follow along live with demonstrations on your own tablet or computer

• Watch and take notes without having to complete every step in real time

• Participate from anywhere in the world with an internet connection

• Join a live interactive Q&A after each session with Dallas Harvey

• Ask questions about your own prints, molds and FX projects

• Troubleshoot digital and printing workflows directly with the instructor
  
  Ready to add resin 3D printing to your makeup FX or prop workflow? Register now and learn the complete process from digital model to finished print.