I need about 50 foam skulls. I realized that buying is much less economical than manufacturing. So I used a set of Rebound 25's to make a silicone mold of a simple skull. I could probably use 3/4 of the set instead of all, but this was my first time making a mold. I honestly asked if one set would be enough for me and was pleasantly surprised. I found the product to mix and spread easily. I used thickener for all layers after the first. Then I made a two-component plaster shell for it from the rest of the modeling plaster. I used a two-component foam and was very happy with the result! Update - decided not to stop at a skull. A total of 3 1/2 sets were used to take 2 full skull casts, one without jaw cast, one flat back cast and one jaw cast. I used a 2 lb polymer planetary urethane expansion foam kit and got 29 skulls on the first run. There is a learning curve for both the mold making process and the two-component foam. I feel like now I could do it all all over again with just 3 kits and get 35-40 skulls with a gallon kit. I'm making a massive catacomb that looks like a bunch of fake bones, so I don't need it very dense. It worked well and ended up fetching me about $2 a skull.
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