Adam Savage Attempts Spray Casting Props!
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- čas přidán 2. 08. 2023
- Adam has long wanted to try his hand at polyurethane spraying for propmaking, and he gets a crash course in PU spray casting at the workshop of FBFX! Prop maker Laurence Moore guides Adam through making realistic stunt helmets in their PU spray booth, a process that can yield 60 helmets a day! As Adam soon learns, the casting process is fast, messy, and requires some technique and practice to turn out usable parts!
Learn more about FBFX’s work at www.fbfx.co.uk/
Shot and edited by Josh Self
Music by Jinglepunks
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#adamsavage #movies #props - Věda a technologie
Learn more about FBFX’s work at www.fbfx.co.uk/
lol pinned 2 days ago, released 6 mins ago
Saw a video where someone used a soft nozzle air gun to easily separate stuck buckets, would the same idea work for their hard molds as the cowboy hat moment brought it to mind.
ok Adam: Next episode, you get to spend a day applying faux finishes to the helmets you made, would be awesome to see how they finish up
i love that Adam has enough basic knowledge of the process to ask questions that make sense and are not completely basic. His enthusiasm is infectious.
I agree but he is a also a great interviewer
that's common sense your talking about mate. we should all have it.
It would be so cool to see Adam finish the surface/weather of one of those.
That should definitely be a part 2.
I wonder if he got to take them home?
@@Calamity_Jack Was what I was wondering as well.
Only reason I could see him not taking them is because of the shipping cost for such big boxes back to his home in Cali. Doubt the material can be recycled, so there'd not be much reason for FBFX to keep them.
Coming up next on Tested...😂
you can tell my man is used to getting those done fast, no time to waste letting Adam figure out how to get them out of the molds lol
Definitely. Dud knows exactly how roughly he can treat them and goes there.
I'm surprised he doesn't used compressed air to release them from the mould though
@@jamesbrown99991Might help. It's another thing to be messing with though.
I love the Last couple of videos where Adam does things he's never tried before. It's like one day builds but with the enthusiasm of teenage Adam lol.
No word of a lie, I worked for these guys 20 years ago in their old workshop. Had a summer job while I was at Uni and worked on Troy. Hands down the best job I ever had and the ber firm I ever worked for. Was lucky enough to go back to them a few times to work. 20 years on and still miss it
Those powered air-purifying respirators are the absolute bees knees, kinda surprised Adam hasn't used them before. I just couldn't work without them anymore personally.
I suspect we’ll see it used in a space suit for cooling for a con before too long…
Yeah they’re mandatory PPE where I work at least. They come with HEPA filters and some models are EX-proof, though they are 10x the price 😅
@@JFlatby Welcome to the joys of the English language, feel free to substitute "bee's knees" for "dog's *dangly spheres*" if you prefer 🤣
@@JFlatby It's the cat's pajamas, pal!
i can see adam adding one to each of his space suits for the comfort
Adam walks into a shop he's never been in before, using materials he's never touched before, and ends up being 80-90% successful on the first try.
That's an example of "transferable general skills" right there. :)
Adam's excitement is so infectious!
Except if you're that guy I guess...
The other guy was nervous unfortunately. Adam wanted to demold them, and look at each one but the other guy was rushing through it.
@@AmazingFrenchman Let's see you do on-camera in front of Adam Savage! He's an off camera guy on camera. He did fine, give him a fucking break.
@@RickR69 Jokes. Laugh. Fun.
@@hippopotamus86 you can tell he's used to working quickly.
Would love to see a one day build video of Adam finishing these helmets if he got to keep any of them.
My wife, an occupation hygienist, commented that Adam should be using one of these set ups for everything, as he has a beard a normal mask won't seal correctly.
That's one of those "everybody knows" bits of wisdom that gets passed along that is just plain wrong. What kind of beard has a huge effect on whether a mask will seal effectively or not. Adam's got a similar length and thickness of beard to me (his is a bit thinner in fact) and my face and beard have passed a full respirator pressure and leak test with flying colours. In fact everybody, regardless of beard or not, should do a full pressure and leak test to ensure that their respirator fits properly and they are wearing it correctly.
@@ianmason. Just dare to try out my country's, military gas mask/tear gas test that the new guys go through each year. Even the instructors shave for that day.
@@Renee_R343 As my father, an Army sergeant, used to say: "There's three ways to do everything. The right way, the wrong way and the Army way.". I'd happily go into a chamber with tear gas with a properly fitted respirator and my beard. I've worn respirators in the presence of much more harmful things than tear gas. I'm not sure that I'd want to do it with a military gas mask; the lowest bider, one size fits all attitude that goes with military procurement doesn't inspire confidence.
@@ianmason. I'm not the worrying kind, or concerned about every little detail either. I just meant that not everything is perfect, even if we often would like to think that they are.
It’s so cool how you can just crank them out so fast. Even removing them from the molds was a breeze. Awesome process.
Ya, pretty impressive and with like 3-4 identical molds, looks like a team of 3 people could churn out hundreds of these in a day.
One to spray, one to de-mold, a third to reassemble/prep, rinse and repeat.
This is interesting. It's basically the exact same process for those spray on truck bed liners. They have a big air compression gun that heats and sprays the 2 parts, they mix in the air and cure very quickly on contact. I wouldn't be surprised if it was the exact same stuff.
The components mix in a chamber before being sprayed, but yes, this is the same method, and same material. Called Polyurea. Industry's little secret they're calling it intentionally polyurethane.
@@h4z4rd42 Oh interesting! Thanks for the correction.
@@h4z4rd42 Is it *really* intentional as to mislead people ... or is it simply a consequence of one sounding a lot like an abbreviation of the other even though it isn't ?
@@h4z4rd42Ah! I was wondering why they acted like "PU" was something special, then said it was plain old polyurethane. Even Adam seemed a bit confused in that moment. Thanks for the info.
@@piorism I'm working with both materials, also as a propmaker. Therefore I think it would be a rough mistake to mix up those stuff by accident.
Btw polyurethane isn't an exact material, there are hundreds of materials with very different properties based made of it from optically clear resins through elastomers to rock solid casting resins and foams of course, but none of them are sprayed at high temperature. But polyurea is. Experts tend to keep thei secrets what is uderstandable...
Polyurea is widely used in the film industry. My first experience was in 2013 during the making of Hercules -the trachian war, where we sprayed armour pieces. We also had hundreds of shields made in the same material came in a 40ft container. I was told those were made for the Gladiator movie (shot in 1999), all we had to do is to repaint them.
This stuff is literally indestructible.
What I love about this channel is how it adds so much the overall enjoyment of videos seeing someone really seem be genuinely loving and having fun with what they are doing the way Adam does.
What a wild technology! I am really hoping Adam got to bring some of his attempts home!
It was hilarious & refreshing to see a grown man get so freaking excited about trying this process for the first time! Adam looked like he could hardly stand not being able to move faster! Haha.
Awesome video because I never knew about this stuff!
Thi is a testament to the quality of work from their mold makers. Fun video!
It's really cool how that dude is just so used to doing this super fast, it looks like he can't even slow down for a video. Nice!
Yeah, the material sets so quickly, there's no time to waste.
I love that there's always something new; a material, a process or a technique that advances the craft. Saving time and effort or improving quality, it must keep things interesting, even for those who have been working in the field for years.
oh, i love Adam in this situations so much. Especially this reality check moment when Laurence says he only "maybe" hire Adam. so fun
I love how Adam knows enough to ask really well informed questions.
The sheer delight in Adam's eye makes this a fantastic little look into special effects. Thanks for bringing us along!
Adam, I made the Winged-Hussar helmet on the left... That was cast from my master-armour for the film 1612.
As a point of interest the helmet and associated armour took me six months to make, but FBFX spray-cast 42 complete half-armours in one weekend, whilst there was a private plane on standby waiting to go to the location.
The master armour has a one-piece siege-weight steel skull, and weighs a hefty 3.2kg, whereas the Polyurethane helmets weigh abut the same as a packet of biscuits... Cookies for you on the other side of the pond.
Keep up the great work and give my love to the mad-scientists as FBFX. 🇬🇧⚒🇺🇸
I've commented this sentiment on Adam's videos before but it bears repeating. His enthusiasm for the subject matter comes through so palpably that it makes this content compellingly watchable. And I have to believe he's encouraging people to become involved.
I have so much admiration and affection for both the man and the craft.
I’ve been spraying a material very close to this and also this material for 15 years or so. Have made molds out of it many times for carbon fiber work. It usually gets sprayed into truck boxes and on industrial equipment.
Loving these visits to various craftsman workshops. Great stuff.
I always like to see a master in his craft learn a new technique. Never stop learining.
These behind the scenes videos are wonderful! We want more!
What a great technique. Very cool. Thank you for showcasing this.
im constantly envious of all the cool tools adam gets to use!
Really loving this content and the enthusiasm on display!
Incredible way to make something so fast yet look so real once finished !!!
It's like a low-volume, artisanal injection molding
Love it when Adam visits us here in the UK ❤
Tested going from strength to strength these days, just knocking out brilliant videos!
An amazing process, wow
i didnt think id enjoy this as much as i did.
what a great video
Fun to see how you can still learn. Those masks with overpressure I used for the first time in 1995. They are great!
Oh I'd love to try that! Such an amazing process and I'm shocked at how quick you can produce parts!
I can see so many applications for this, especially for large molds.
adam enjoys this a lot and his joy is infectious
Very informative, and interesting. Thank you 👍
This was brilliant!
i do this for a job and another cool thing you can do is spray a silicon mould with a cellulose paint before you spray the pu so it comes out painted.
I've seen various powders used in resin casting too (like iron powder to give a rusty finish). I'm guessing you could use them here also.
Amazing process. I bet he brought all of them home.
Fascinating!
That Exodus helmet is great! Would love to add that to my collection.
Lee Pace ,who played Thandrill from the Hobbit, would volunteer to work in the effects shop making armour. It really is addictive🛡️⚔️🗡️
Worked at a boot company that made treads out of a very similar poly blend. We used injection molding instead of a spray, but the bubble voids are the giveaway. It was pretty awesome stuff, and it makes for a pretty comfy stool topper if you increase the foaming rate. Probably similar to the blend for stunt props that he mentioned at the end.
Really cool, we could see Adam was having a lot of fun making them. Did he get to take the fails home?. ( Future one day builds )
I have tried this 3-4 years ago. I went to a polurea compagny with a silicon mold of a brestplate. I learned about this in your lich king armor video. Wyrmwick uses this techmique. I think they spray over real metal armor pieces. It's the finish that made me switch to something else. At the end of the day it is still a flexible rubber-like part that is painted. It looks good from a distance but it does not feel like the real thing at all when your have it on.
I was watching this with my mouth open all the way. I am amazed at this :O
This is very cool, and you can see this is a man who lives with tight deadlines daily, and Adam's respect for that.
A simple thought (from a simple mind), could you use compressed air to aid the demolding process somehow, or would that just risk breaking the casting?
Maybe a plug that goes somewhere inconspicuous, remove plug, blast air, out she comes.
This could be a good idea, this is the best way to unstick buckets when they fuse themselves together. Blast some air between them and voila!
Great Adam sir
I've done this job before. It's fun work but presents a lot of interesting challenges, you REALLY have to have a solid ability to conceptualize 3D spaces in your head to know where you need to go thicker or lighter in the mold. Having experience traditional sculpting, 3D modeling, and CAD/CAM comes in SUPER handy in this sort of spray work. I was really good at it but I was DEFINITELY much happier outside in the priming booth priming large rotocasted parts or final paint doing all the hand brushing after initial paint. Very monotonous stuff but much less involved than spray casting. I will say though having a forced air mask is a lot comfier than just sweating buckets in other parts of a hot workshop. Most recent shop I worked at had a whole department of guys who's enitre job was just cutting and sanding flashing, and patching little stuff with Bondo for parts like this. Now mind you, nothing we made was meant to be worn by people so we could get away with a hasty patch job on a lot of stuff.
Great to see you in the UK. Im sure we are giving you a warm welcome 👍
its england, its FREEZING
@xaracen7207 Ah, that's why I said warm welcome! I didn't want to mention the weather at the momemt as its bloody wet too.
@@3DPFactory1 fair.
Such a cool video and wonder if using tiny bit of air would get molds out quicker works with other stuff
Laurence Moore, Adam's trainer here, is brilliant for just being straight forward with what went wrong for quick learning
I love that classic adam look where he looks over his glasses to look at something close
a blast of air in between the mold and cast, would help greatly
What a smart way to make props
Adam found a new favorite 'dust/vapor' mask, we shall see if he gets one to use in his shop :) The audio was great even with it too.
Amazing. I want to do it. Is it the same stuff as they use for truck bed liner, or a different blend?
Nice one man!
The most exciting thing to me with Adam sharing videos of these processes, is that makers are going to figure out how to do this process at home with less expensive equipment. Give it a few years, and makers will be able to do this kind of process in their garage for their own projects.
That spray gun setup looks like a badass sci fi gun if ever I saw one ^^
I would love to see how they paint these.
You can tell Laurence wanted to get shit done haha! Really cool process and seeing the results was fantastic.
I had a couple thoughts:
Can they do that with clear PU to make lenses?
Could they do other colors? I'm thinking spraying white stormtrooper armor would outfit the whole 501st in short order.
Could they use microballoons or glass fibers between layers to add volume? Would it be necessary? Would it just be itchy as hell?
Soon, that spray booth is going to have a perfect polyurethane mold of the whole thing. They could just peel it out and have a whole new plastic spray booth.
I'm curious what the "failure" rate is for these for experienced sprayers. I'd expect that a lot of these helmets would go to background guys in a big medieval battle, so how "perfect" do they need to be? Sometimes he says "it's too heavy," but how heavy is it, really? I'd think heavier would be better than lighter.
I'm guessing heavier in this context just means heavier than it needs to be.
Those respirators are absolutely fantastic
They're a must for serious woodworking. But they're not cheap.
@@the_arcanum yeah and knife making they are so much better when using a grinder
As someone who researches sprays of weird fluids, I love this.
I would've enjoyed seeing how the helmets received their final finishing (metal appearance). Thanks for the interesting video.
Reminds me a pin-striping on cars. Really takes skill.
A cool process and Outbreak cosplay at the same time 😂
Fascinating! It seems like a far more flexible tool than vacuforming.
Would love to see a Stormtrooper outfit made entirely with this process.
reminds me of spray on bed liners for trucks
Wow!!! The Corinthian style Greek helmet displayed on the back is truly captivating, reminiscent of the authentic ones found in the Archaeological Museum of Ancient Olympia.
You needed two things to de-mold that cowboy hat, compressed air and blow chuck. If it works for handlebar grips, it will make the props pop out with less stress in the parts and molds.
I thought that they would be using one of those really slim air gun nozzles to try and get the material to come loose from the mold.
Maybe it's not such a good solution as i thought, but the absence of it makes me wonder what's so bad about it.
So are we going to see build videos for these helmets?
Amazing!
Now can we also see a video abotu how they apply the metal finish to the moulded helmets? I would have though they'd put metal powder or paint in the mould first and then have it stick in the material. But it's added after? How? Is it durable being added after?
That is SUCH a cool process, I cant get over how fast they were to produce. Outside the master and mold making of course. I want one of those rigs, that's absolutely amazing.
That was cool
Once you know the expansion and get the feel, its just feel. That's awesome. Adam needs a booth for this. He'd have a cosplay anytime he made a mold
my only guess is these guns require a large up front cost
@@AsbestosMuffins as with anything. But he has the whole Tested team to use it as well so it's spread out
@@AsbestosMuffins My man are you under the impression that Adam is poor?
@@ssl3546 No but it needs a quite a lot of room he doesn't have in his cave... But honestly, this kind of setup built for studio work and high volume replica production doesn't fit his needs. No need to even make a mold when you have printers able to output a complete prototype suit for one person. And Adam has shown many times he is not shy of contracting specialized crafters and propmakers for a specific costume.
who knew you could make hats out of bedliner???
Not really bedliner but something cooler
great video
Wyrmric Armoury in the UK developed this technology 20+ years ago. They sell their armour to the general public.
A quick jolt of compressed air between the mold and the part will probably get it out quickly and without tearing
15:54 Looks like Adam is holding in all his giddy-ness, you can tell just how much this excites him. Its even making me excited too!
Thats kinda cool :3
Very cool process. I wonder if you could do sonething similar at home using like, and obscene amount of a commercially available rubber spray like plastidip.
Will there also be an 20cm (instead of 15cm only) SI-Units only version of the forearm ruler?
Now I want to see how he paints the helmets to give then a metal look
I'd like to see how they're painted to get the metal look.
COOL !!!!!!!!!!!!
Next week on tested : Adam sets up his own spray set up and makes EVERYTHING lolol
PAPR’s are the best!! I wore one every shift for 15 months as an RN on the Covid Floor
I love how that room is like 50% fine, and 50% complete disaster area. :D
I recently watched a video where they were electroplating 3d printed pieces, would be cool to see if you could electroplate these.
"I'm dying to help you." Same energy as a kid going to a candy shop!