Hey Guys,

So I'm building a robot puppet and I would like to try something different from the last one I made. The last puppet was made with plastic parts and then spray painted. The robot works great but I want to try something new. I want to make the next robot out of foam and then coat the foam in something to make it smooth like metal for a robot. I am hoping to still have some flexibility in the head.

Any ideas? What should I put on the foam to make it smooth?

here is a link to our first robot if you have not seen it.



thanks for any help you can give.
Jon Little

I love that robot puppet.............. Are you just wanting to try a new technique? or and some animatonics to it? Great video.

Billy D.

I like your robot too.  I've admired him before.

I haven't tried this yet, but I've heard of a product called "sculpt n coat" that you can spread over foam to make it smooth and shiny.  I heard about it from the people who wrote the Foam Book - Grey Seal Puppets.  I have their DVD.  Perhaps it's in their book as well. 

can you pick up the Sculpt n Coat in stores?

This next puppet will have some LEDs if I can figure out how to hook them up. Anyone ever use LEDs in a puppet that can tell me how to do an easy switch for them.

Sculpt or Coat is available at http://www.sculpturalarts.com/foamcoating.htm . I'm not sure how many coats it would take to get things really smooth, but it does put a nice stiff shell-type coating on the foam. It might even be a little bit sandable (I haven't tried that). I've not seen it in any stores, but West Virginia isn't exactly an easy place to find some of those more unique products. (On the other hand, N. Carolina isn't far away, and it only took a couple days for UPS to bring it to my door.)

I plan to use it to cover a foam puppet, then paint it to make the puppet look as if it was carved from wood, rather like Pinnocchio.

I think your best is easiest way to achieve your goal is by getting the shiny stretchy material, you can find this material usually in a wide variety fabric shop. 

The Sculpt and Coat is great for "parts" (eg. horns, noses, teeth ect) of the puppet I would not suggest covering all of it with the stuff.  If it gets a warm it will start becoming sticky and gooey so you really need to be careful with the stuff. 

Daryl H

Thanks Daryl,

what about doing something like this as a structure for the puppet.

http://www.instructables.com/id/How-to-make-a-cardboard-costume-helmet/

cardboard? interesting...wouldn't think that would hold up in the long run, but who knows.
I was going to suggest Sculpt -n-Coat too (Daryl - that's good to know, I would have tried
to coat the entire thing - thanks)
I like the idea about the shiny material...that's my 2 cents...LOL

Onath stay with foam to make the puppet and use the material to cover it.  You will see the seem when you sew the material but you could use the seam like a metal seem by drawing rivets on each side like a real metal being put together.  I think if you keep the robot fairly squarish (if such a word?) then you could keep the seems to the back if you don't want any seems to show in the front.

I would be worried about cardboard wearing quickly with sweat ect.....

Daryl H

Ok cool thanks guys. Anyone have ideas on how to make an LED light up in a puppet?