Technical make of a prop knife and its casts
For this project, I had exact measurements which I had to follow to get the perfect recreation of the primary template and visualisation of the product. I got a template which showed multiple sides of the knife and all possible measurements to ensure the knife is made just as designed. After making the main prop knife I had to make casts of it in resin and rubber with different finishes. Before casting I had to do a box 2-part mold for each part of the knife. First resin cast had its blade and handle being mixed with mettalic powder, and the other two had to look the same but the difference being that one is made of soft rubber and the other one out of resin.
Starting to cut out the handle with template
Measuring the wanted curves of the edges
sanding the edges to get the desired curves
Making the middle part of the knife
Cut out and sanded aluminum blade starting to be polished
Primed handle
Primed middle part
Polished blade
Making mold and cast of the blade
Making mold for the handle
Finished handle mold
Finished prop knife
Finished prop knife
Rubber cast of the knife
Rubber cast of the knife
Resin cast of the knife
Resin cast of the knife
Resin cast of the knife with metallic powder mixed resin
Resin cast of the knife with metallic powder mixed resin