The following is an outline on how Hard Props are created, from design to physical construction. Please bear in mind, that this is an informal textbook outline. In real life, several of the steps mentioned could be repeated several times. This depending on the requests from the Production Designer, Cinematographer, or Director.

Let's say that we are going to design a Laser weapon for an upcoming Sci Fi Television show. The first step would be to have thumbnails created. Thumbnails are just idea sketches of the prop. They show three quarter views of the object to show perspective. Several of these thumbnails would be created by the Art Department. (See Photos of thumbnails)

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From there, these thumbnails would be given to the Production Designer for approval. The Production Designer would choose, let's say five of the thumbnails that he or she likes. The Production Designer would then send the five choices back to the Art Department for further development.

The Art Department would develop with greater detail the sketches and then resubmit them back to the Production Designer. The Production Designer would then either request more development on the sketches or simply choose the one he or she likes the best.

Final Color Ideation

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Upon choosing the best Ideation, Orthographs would be done. An Orthograph or "Ortho" is a marker rendering of the prop from top, front, side and bottom. The Ortho will also have "ball park" drafting specifications on it.

Once the Ortho is approved, the prop is then drafted for specifications. The reason this is done is for the later creation of a Three Dimensional prop or "Input Model". The drafting process also serves for the creation of copies of the prop that will be made. The Prop Department can also do drafting of the prop as well.

An Input Model, is a Three Dimensional representation of what the prop will be. It is also a more refined version of the prop. The Input Model can be made from either a soft material such as Blue Insulation Foam or "Blue Foam", Balsa Wood, any Oil based or Polymer clay, or a hard material like acrylic. The selection of which material used depends upon which is easier to sculpt the prop out of.

Once the Input Model is approved, it is then sent to the Prop Department. The Prop Department will in turn create the finished prop that will be used for the Television show.

As mentioned above, the Prop Maker can draft the prop for specifications. This depends upon whether drafting specs were provided. A Prop maker will look at the prop and determine how the prop is to be cast. The Prop Maker will choose a hard material in which to make the prop out of. Acrylic, wood or metal is generally used because it can survive the molding process. Once the acrylic, wood or metal version of the prop is created the mold making begins. The Prop Maker will look at the prop to determine how many molds need to be made for the prop. For example, a Hammer would require about 4 to 5 different mold sections to make a Prop Hammer. The most important factor is the undercut. Take for example a model of a Vase. (See Pic of Vase)

The top edges of the prop and the bottom sides of the base are what is called the undercut. This type of prop will require a mold that is two pieces. The seam of the prop will run right along the side of the vase. In propmaking the rule is, "Pour and Pop". You want to pour the material and when ready remove and paint it as quickly as possible. The two piece mold illustrated below will allow the "Pour and Pop" process to occur. If the seam of the two piece mold was running horizontally instead of vertically, the prop edges or undercut would get caught in the mold. The prop could not then be removed, unless the mold was broken.(See Pic of seam lines)

A prop can be simply sculpted out of wood, then painted and sent back to the film company. Hard Rubber can be used to create a finished prop, as well as Fiberglass Resin. Fiberglass Resin is a material that is made from two chemicals, a base and a solidifier or "Kicker". Fiberglass Resin is similar to the Bondo material one would use for patching holes in automobiles.

Props can be made from many materials. But the over-riding factor is the budget. The allotted budget set for the Property Department can determine whether the props are made of hard rubber or fiberglass resin. In a textbook world, all props are cast in molds. In the real world the budget is the over riding factor. Some props are simply purchased from a store.(Example: The communicator used in Star Wars Ep 1 was a modified Lady-Bic Shaver.)

No matter what the prop is, the materials used in prop construction depends chiefly on the budget, the material the Prop Maker likes to use and what the prop will be used for.

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Choose from the following subjects	The Definition of a Prop	The Types of Props
The Creation and Construction of a Prop.	Advice on Kit Prop Building.	Prop Collecting.
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