I am creating a sword for cosplay, and I need the material used to be clear, rigid, and lightweight, and to cure properly in such a thin mould (and can be poured into the mould I have, as I'd prefer to not start an entirely new process, although I'm open to any suggestions).
I have a mould made from a platinum-cure silicone rubber. It's a pretty simple shape with a 3mm thickness.
I have attempted to use a fast cast urethane resin, with a shore D hardness 72 that is clear.
The material I used is mass sensitive (cures better at a greater volume/thickness), and does not get very rigid since the mould is quite thin.
Are there any other types of plastics I could use that meet my needs?
I can include pictures of the shape I've tried to cast if that would help, or links to the products I've used so far.