There are several methods of making prototype replicas using thermosetting urethane, including the vacuum cast-molding, centrifugal cast-molding and atmospheric cast-molding methods.
In the case of the Senshi no Ju replica gun, all the parts are formed by centrifugal cast modeling. For this product, Yuvi Zoukei developed an original centrifugal forming machine in order to realize low-pressure clamping and low-speed rotation. This new machine virtually eliminates both the product deformation that is caused by casting pressure and the mismatching that occurs on the parts surfaces as a result of cast rotation.
Thanks to these production improvements, kit products comprising large numbers of parts now have an even higher quality finished form and they look even more realistic after assembly compared with conventional kit products.
(Note)
The Centrifugal cast-molding method: This is a method of injecting material into a mold using the centrifugal force generated by rotating a round-shaped silicon mold. This method can also be used for simultaneous production of many kinds of products by arranging multiple prototypes within a single centrifugal silicon mold.