1. Creating the basic shapes from the CAD drawing
Working on the component models for the silicone tooling stage. all the components are all made by hand, lots of carving, shaping & finishing.

2. Testing the components
This was early stages of the development, but the basic shapes were completed and being finalised.

3. Spray and finishing
Moving on with the shaping, creating precise detail
for the head, arms and body, all the components
are individually shaped.

4. General assembly
An assembly of the components was completed,
the arms were on pins so they fitted to the body tightly, and they were ready to have the final undercoat before they went to be silicone molded.

5.Producing the tools for the resin
Plastic boxes were produced to hold the silicone,
The boxes are water tight, and the components are suspended inside with rods, this is for ease of use when pouring of the resin, it will allow for hand casting, as the rods attached to the components are set so the resin will fill in all the details once the resin it has been poured inside the silicone.

6. Silicone casting
Once the silicone is poured into the boxes,
They are then put into a vacuum tank.
This remove all the air bubbles from the silicone,
so when you pour the resin into the silicone tool, the the models come out from the tool perfectly.
If the tool has any imperfections in it, you will see these in the final design.

7. Producing multiples of the components
The white block in this image is a silicone tool created in the same way as images above,

This tool is a simple one part tool, you can pour the resin into it from the top, we call this top feeding,
and in around 10 minuites, the air drying resin is set and you can pop your components, in this case theses are lunartik's eyes.

8. Spraying and testing resin components
This model is a full resin piece, it has been produced the same way as the eyes, but the tools are more complex, this model has been sanded down, sprayed and finished, with the eyes in place.

9. The first resin batch hot off the mould
Here is the first set of lunartiks, straight from the mould, they all need lots of work to finish them off to a high standard. They also need cups, and extra customising to make them more interesting.

10. final spray job, and finishing
Little lunartik looks very cute as he pears out from his tea cup, he stands around 200mm tall.