Prop Making Course

Lesson 1 • History and Industry Overview

Traces prop making from theater origins to film, TV, and live events. Establishes why historical context shapes modern material and technique choices.

Lesson 2 • Safety and Workshop Fundamentals

Covers personal protective equipment, ventilation, and chemical handling basics. Safe habits established here apply throughout every subsequent chapter.

Lesson 3 • Prop Categories and Terminology

Defines hero props, set dressing, practical props, and breakaways. Precise vocabulary enables clear communication with directors and art departments.

Lesson 4 • Professional Roles and Workflow

Maps the prop master, prop maker, and art director hierarchy. Students understand how their work fits into broader production pipelines.

Lesson 1 • Adhesives, Fillers, and Sealers

Evaluates contact cement, epoxy, hot glue, and body filler for bonding and surface prep. Correct adhesive selection prevents delamination under production stress.

Lesson 2 • Plastics and Thermoplastics

Introduces PVC, acrylic, Worbla, and Wonderflex for forming and detailing. Understanding heat thresholds enables safe shaping without material degradation.

Lesson 3 • Metals and Wire Armatures

Covers aluminium, steel wire, and sheet metal for structural armatures and decorative elements. Armature design determines the longevity of soft-bodied and articulated props.

Lesson 4 • Foam Types and Properties

Compares EVA foam, polyurethane foam, and upholstery foam for density, flexibility, and carveability. Material choice directly affects fabrication speed and final appearance.

Lesson 1 • Shaping and Grinding Tools

Introduces angle grinders, belt sanders, and oscillating tools for rapid material removal. Controlled shaping at this stage defines final prop geometry.

Lesson 2 • Measuring and Marking Accuracy

Establishes use of callipers, rulers, squares, and templates for precise layout. Measurement accuracy at this stage prevents compounding errors in assembly.

Lesson 3 • Cutting Power Tools

Teaches jigsaw, band saw, scroll saw, and rotary tool operation for complex cuts. Accurate cutting reduces material waste and downstream finishing time.

Lesson 4 • Drilling and Fastening Tools

Covers drill press, cordless drill, and screw gun for assembly and hardware installation. Proper fastening ensures structural integrity under repeated handling.

Lesson 1 • Scaling and Proportion Control

Applies grid scaling, reference photography, and measurement checks to maintain accurate proportions. Proportion errors are most efficiently corrected at the sculpt stage.

Lesson 2 • Epoxy Putty and Two-Part Sculpts

Covers mixing ratios, working time, and finishing of epoxy putty for hard detail additions. Epoxy putty bridges sculpting and rigid fabrication in a single material.

Lesson 3 • Texture Creation Techniques

Demonstrates stamping, pressing, and carving methods to replicate stone, wood, and organic textures. Convincing texture is the primary visual cue for material believability on camera.

Lesson 4 • Foam Carving Fundamentals

Teaches hot wire cutting, knife carving, and sanding to shape EVA and polyurethane foam. Foam carving is the fastest route from concept to three-dimensional form.

Lesson 1 • Mould Design and Planning

Covers parting line placement, undercut analysis, and mould type selection before any material is poured. Good mould design prevents tear-out and reduces material waste.

Lesson 2 • Resin and Urethane Casting

Covers two-part urethane resin mixing, pressure pot use, and demoulding for rigid castings. Pressure casting eliminates surface bubbles that would require extensive finishing.

Lesson 3 • Rigid Mould Materials

Introduces plaster bandage, ultracal, and fibreglass mother moulds for supporting flexible moulds. Rigid shells prevent silicone distortion during repeated casting cycles.

Lesson 4 • Foam Latex and Flexible Casting

Introduces foam latex and flexible urethane for soft props, creature parts, and wearable pieces. Flexible castings require different demoulding and finishing approaches than rigid parts.

Lesson 1 • Airbrush and Spray Painting

Teaches airbrush setup, pressure settings, and paint dilution for smooth gradient finishes. Airbrushing enables subtle colour transitions impossible with brush alone.

Lesson 2 • Weathering and Aging Effects

Applies washes, chipping, rust simulation, and grime buildup to create aged and battle-worn props. Weathering is the primary technique that sells a prop's history to the camera.

Lesson 3 • Surface Preparation and Priming

Covers sanding, filling, and priming sequences for foam, resin, and wood substrates. Proper prep determines paint adhesion and the smoothness of the final finish.

Lesson 4 • Brush Painting and Dry Brushing

Demonstrates base coating, layering, and dry brushing for texture enhancement and detail work. Brush techniques add tactile realism that spray alone cannot achieve.

Lesson 1 • Breakaway and Stunt Prop Construction

Teaches sugar glass, scored foam, and pre-weakened joints for safe breakaway props. Stunt props must break predictably to protect performers and maintain continuity.

Lesson 2 • Testing and Reliability Protocols

Establishes rehearsal testing, failure mode analysis, and backup prop preparation. Systematic testing prevents on-set failures that halt production and damage budgets.

Lesson 3 • Pneumatic and Hydraulic Mechanisms

Introduces compressed air cylinders and tubing for rapid-action prop mechanisms. Pneumatic systems deliver repeatable, fast movements that servo motors cannot match.

Lesson 4 • Electronics for Practical Props

Covers LED circuits, battery packs, switches, and basic microcontrollers for illuminated props. Low-voltage electronics expand the range of practical effects achievable in-house.

Lesson 1 • Handoff, Strike, and Storage

Defines prop handoff checklists, on-set care instructions, and post-production storage protocols. Proper strike and storage preserves prop value for future productions and rentals.

Lesson 2 • Documentation and Prop Tracking

Establishes prop lists, photo logs, and condition reports for tracking every item. Thorough documentation supports continuity, insurance claims, and future rentals.

Lesson 3 • Scheduling and Milestone Planning

Teaches backward scheduling from shoot dates, milestone setting, and buffer allocation. Milestone planning ensures hero props are finished and tested before camera days.

Lesson 4 • Sourcing and Vendor Management

Covers supplier research, purchase orders, and lead time management for materials and found objects. Reliable sourcing prevents fabrication delays caused by material shortages.