What casting materials are lightweight and durable?
Don’t do plaster, it tends to be unstable and crack. Try a liquid resin. They last a long time, can be casted in different colors, and hold paint well. If you mold in resin, its prolly best to use rubber silicone for the mold. Then pour the resin (mixes in two parts) into the mold and it hardens in a few minutes. Then pop the resin cast out of the mold.. Just google for the molding materials and you will find a good variety. My friend and I have molded replica movie props over many years and have been very successful with this method.
