Reusable Casting

How can I make a cheap reusable mold for an arm cast?

I want to make two arms that can have a variety of hands in different poses that attach to them. Since I’m making two arms, I want to have a reusable mold. The material for the cast will also have to be lightweight and easy to carve out a piece (so that I can attach the hand). What do you suggest I use for this? Keep in mind that I’m working on a teenager budget, so I cannot afford much.

The easiest (and cheapest) material is plaster of Paris and cloth – gauze holds more plaster but cotton cloth holds enough. Because flexible materials are expensive, you will have to make a two part rigid mold that goes half way round the arm the right way and even that will have to be coated with vaseline as a release. If you know a friendly nurse, med tech or doctor, you can wrap the arm and have the “cast” cut off with the reciprocating blade tool that doesn’t cut flesh which is used by them to split casts. Failing that, you will have provide your own dividing lines and lay down half the cast then coat the edge and do the other half.
Strongly suggest you practice this application and removal process on a small section that you don’t mind destroying if things go wrong.

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