This guy is making a head cast for creating armour, so a fairly relevant application.
https://youtu.be/6eQFlmmtxKo
If you used a two part expanding foam, you wouldnt be limited by trying to air cure a large volume of spray foam. Plus the density will be much more even. Spray foam tends to finish with some rock hard areas and soft pockets of mush.
http://www.mbfg.co.uk/foam-materials/foam-hard.html
I need to make a copy of my head.
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