A lot of people ask me how I break models down into pieces for casting without damaging them. The truth is that some amount of damage is unavoidable, but by planning ahead you can make it easier to avoid significant breakage. I took a few photos of the Archangel as I was separating it into the main components for the master castings and thought I’d share them so you can see the process.

Here I’m separating the arm from the shoulder using a hobby knife and a large, flat chisel blade. First I heat the model with a heat gun so it’s easier to cut, then I carefully slide the blade in until I feel resistance. I repeat this all the way around the shoulder.

To avoid the surface cracking or breaking, I cut all the way around the shoulder before cutting through and into the armature.

I had to tap the knife handle with a pair of pliers, gently forcing it through the aluminum armature.

Here I’m separating the tail from the body. I carefully removed a chunk of the sculpt to reach it, but it will be glued back into place and repaired.

I planned in advance for the separation of the Archangel’s head. Because its mouth was going to be open, I knew the mold room would want its head cast in three separate pieces. I separated these pieces when I constructed the armature, then lightly super-glued them back in place before sculpting the head details. All I have to do now is cut the sculpt at the pre-existing break and the parts pop right off, clean as a whistle!

So, as you can see, there’s no real magic trick. It just takes patience, hard work, and the skill that comes with years of experience.

Until next time!