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Advanced Lifecasting

Advanced Lifecasting Techniques

In addition to our Accu-cast alginates, our PlatSil Gels may also be used to mold the human form. The following tutorials will introduce you to more advanced lifecasting methods using Gel-10 and Gel-25. Both products may be thickened to a brushable paste with TinThix. We also offer a Gel-25 lifecasting kit to help get you started.

Important! The methods demonstrated on this page are for experienced lifecasters. Practice and more practice and experimentation is the key to successful lifecasts.

In this tutorial we will introduce you to the basics of silicone lifecasting. This is the first chapter of our new Lifecasting 102 DVD.

As a bonus point for those of you who found this page, here's a full head cast tutorial using PlatSil Gel-25 and the novel procedure of using a Gel-25 bald cap that later becomes part of the finished mold. This was the original head cast chapter in our Lifecasting 102 DVD before we re-shot it to explain Neill Gorton's nostril-plugging method. For those curious about Neill's technique, an explanation can be found in Prosthetics Magazine Issue 3 as well as our Lifecasting 102 DVD. This is a long tutorial (~35 minutes), so grab a note pad and a cold drink and get ready to learn.

In this tutorial, we make a front torso mold using thickened Gel-25 brushed onto our model. Much like an alginate mold the flexible Gel-25 mold is then backed up with a supprot shell of Plaster Bandages. It is important to not that the bandages we offer are a very high grade, fast setting medical bandage, NOT hobby store bandages. This is a critical detail that can make or break a lifecast mold.

In this next tutorial, we take the pre-poured keys concept further to create alignment points for a two piece torso mold. The keys were poured up in advanced using a piece of aluminum channel released with 2500 spray release. Important! 2500 release is not for skin! Use Vaseline, Alginate Release, or Petroleum Jelly to release PlatSil Gels from skin surfaces.

PlatSil Gels are also ideal for large body molds. The main advantage is that Gel-25 can be built up in layers allowing a large mold to be made in a time span not possible with alginate. Since silicone has a high tear strength, it may be removed from the model without fear of ripping. Also, a PlatSil Gel-10 mold (as seen in this 2 part tutorial) may be demolded, seated back into its support shell, and cast up at a later date. Alginate molds begin to shrink and distort within hours of removal whereas PlatSil Gels cure to form permanent molds that may be used for years.

In this two part tutorial we mold a model for a cadaver prop using Gel-10 for the body and Accucast's Genesis V for the head. A clay pour was then made. In the video we use the now defunct "TexClay" but you can also use Monster Clay.


A full head cast can also be made using either Gel-10 or Gel-25. In this tutorial we make a head cast of our subject using Gel-10 thickened with TinThix and PolyFiber Thickener. We also used a Gel-10 bald cap which allowed for the cap to become part of the finished mold.

In this next tutorial we give an overview of the process of making a plaster bandage body cast to make a body or dress form. This process is used for making dummys as well as dress forms for cosplay. We used our high=grade plaster bandages for this mold. We do not recommend using this method with hobby store or craft bandages as the mold will not be strong enough for demolding or casting without deforming. Understand that this is also a fairly advanced process. Do not attempt if you are new to the lifecasting process. You can find our Plaster Bandages here.