Core Manufacturing Process Flow

The entire process can be divided into five main stages: [Master Sculpting] → [Mold Making] → [Casting] → [Sanding & Preparation] → [Painting & Finishing].

Stage 1: Master Sculpting

This is the artistic origin, determining the final form of the figure.

· Design: Concept art or 3D modeling.
· Sculpting the Master: A sculptor creates a high-precision master pattern using materials like epoxy putty, polymer clay, or digital sculpting (e.g., ZBrush) combined with 3D printing. This is the most skill-intensive step.

Stage 2: Mold Making

To replicate the master, silicone molds are created.

1. Parting Design: The complex master is intelligently divided into separate parts (e.g., head, limbs, weapons) to allow for demolding.
2. Creating Silicone Molds:
· The master parts are secured in a containment box.
· Liquid silicone is poured in, completely enveloping the master.
· After the silicone cures, the mold is cut open, and the master is carefully removed, leaving behind a cavity mold that precisely copies the original.

Stage 3: Casting (Replicating Parts)

This is the core step for producing multiple resin copies.

1. Mixing Resin: Polyurethane resin Part A and hardener/catalyst Part B are mixed in precise proportions. Defoamers may be added as needed.
2. Pouring & De-airing: The mixed resin is poured into the silicone mold. By rotating the mold, vibrating it, or using a vacuum chamber, air bubbles are removed to ensure the resin fills all details.
3. Curing & Demolding: The resin cures at room temperature (typically several hours). Once cured, the resin parts are removed from the silicone mold, resulting in the “white kit” or “raw cast.”

Stage 4: Sanding & Preparation (Processing the Raw Cast)

The raw cast has imperfections like mold lines, pour sprues, and air bubbles that require meticulous work.

1. Cleaning & De-spruing: Pour sprues are cut away, and any supporting vents are removed.
2. Patching: Modeling putty (e.g., epoxy or polyester putty) is used to fill air bubbles and defects.
3. Sanding: Sandpaper of progressively finer grits (e.g., 400 to 2000 grit) is used to sand down mold lines and uneven areas for a smooth surface.
4. Dry-fitting/Test Assembly: All prepared parts are temporarily assembled to check fit, making adjustments if necessary.

Stage 5: Painting & Finishing

This step gives the figure its soul and requires high technical skill.

1. Cleaning & Primer: The raw cast is washed with soapy water to remove mold release agents, dried, and then sprayed with primer (surface). This unifies the base color, reveals any remaining flaws, and improves paint adhesion.
2. Painting:
· Brush Painting: Suitable for small details and gradients.
· Airbrushing/Spray Can: Used for large, smooth color transitions and shading effects (e.g., Max style, gradients).
· Common Paints: Model-specific acrylics, enamels, oil paints, etc.
3. Detailing & Protection:
· Panel Lining/Washing: Thin paint is applied to seep into recessed details, enhancing depth.
· Dry Brushing: Highlights raised edges.
· Filtering/Weathering: Creates aging or weathering effects.
· Top Coat/Sealer: A final spray of gloss, semi-gloss, or matte clear coat protects the paint layers and unifies the finish.