{"title":"Raw Casts\/Blanks (Garage Kits)","description":null,"products":[{"product_id":"captain-america-shield-2-0-full-metal-1-1-scale-aluminum-reforged-shield-marvel-hero-prop-replica","title":"Captain America Shield 2.0 - Full Metal 1:1 Scale Aluminum Reforged Shield - Marvel Hero Prop Replica","description":"\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cstrong\u003e\u003cspan class=\"\"\u003eCaptain America Shield 2.0 – 65CM Cast Edition – One-of-a-Kind Craftsmanship\u003c\/span\u003e\u003c\/strong\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eThis shield went through two complete remakes, and we even built our own custom polishing machine from scratch. It took over two years of R\u0026amp;D to arrive at what we can honestly call an \"imperfect\" masterpiece.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003e\u003cimg src=\"https:\/\/cdn.shopify.com\/s\/files\/1\/0848\/0437\/0675\/files\/15.jpg?v=1786709907\" alt=\"\"\u003e\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eWe haven't fully solved the natural casting texture that forms during the metal cooling process – a result of the casting cavity being extremely thin. These fine flow lines are inherent to the casting method. If you have strict requirements for flawlessly smooth surfaces, we recommend choosing the Battle-Damaged finish instead, which effectively masks the casting patterns and gives the shield a screen-accurate weathered look.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003e\u003cimg src=\"https:\/\/cdn.shopify.com\/s\/files\/1\/0848\/0437\/0675\/files\/19.jpg?v=1786709693\" alt=\"\"\u003e\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eFor customers who still prefer a cleaner appearance, a light smoked effect effectively conceals water marks and flow lines. On top of that, we can add light scuffs and scratches that do not penetrate the original paint layer. A clear coat is applied over the brushed metal texture underneath – it allows the underlying grain to show through, though the finish may not appear perfectly uniform.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003e\u003cimg src=\"https:\/\/cdn.shopify.com\/s\/files\/1\/0848\/0437\/0675\/files\/02_cdd74f37-e690-41c6-bf8d-6a8164a2340b.jpg?v=1786709692\" alt=\"\"\u003e\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eWe do not spray automotive paint directly onto bare metal. A proper primer coat is always applied first to ensure even, durable coverage – because real quality doesn't cut corners.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eOn display and in photos, the shield presents beautifully. The shape and silhouette are highly accurate, and that's where the casting process truly shines.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eTo achieve a one-piece cast shield, we had to upgrade our entire production line – essentially, we started building machines just to make this shield. In a one-piece cast shield, material density is not perfectly uniform, so unidirectional polishing cannot produce an even brushed grain. The polishing process also generates massive amounts of particulates and extreme heat, sometimes reaching the ignition point. Our custom machine supports bidirectional rotation combined with a water curtain system for dust removal and cooling – the only way to prevent particle adhesion and overheating.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eBecause the metal goes through liquefaction and re-solidification, it no longer behaves like stable, cold-worked metal. This became obvious during the brushing stage – where our 1.0 version had a simple brushing process, the 2.0 casting introduced unexpected graininess and surface imperfections that we had to fight every step of the way.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eOur 1.0 version was made using cold stamping – applying thousands of tons of ultra-high pressure to stretch aluminum sheet over a mold. We went to great lengths to recreate every line and contour, even building a two-layer laminated structure to match the screen-used shield's internal construction, with different details on front and back. Cold stamping is relatively stable with a low rejection rate. The main drawback is that all shapes are formed by stretching metal to its yield point, so it can't produce sharp angles – everything comes out with rounded transitions. The curvature can never be a perfect arc either, which you can see from how light reflects off the surface.\u003c\/span\u003e\u003c\/p\u003e\n\u003cp class=\"ds-markdown-paragraph\"\u003e\u003cspan class=\"\"\u003eOther makers generally avoid the most challenging recessed line designs, using painted color bands instead of actual sculpted lines. We believe ignoring the source material is not the right approach, but we also recognize the limitations of this process. That's exactly why we kept searching for a better way – and that's how the cast edition was born.\u003c\/span\u003e\u003c\/p\u003e","brand":"COSBUYS","offers":[{"title":"Battle-Damaged Finish","offer_id":50284486885619,"sku":null,"price":420.0,"currency_code":"USD","in_stock":true},{"title":"Black Panther Claw Mark Finish","offer_id":50284486918387,"sku":null,"price":420.0,"currency_code":"USD","in_stock":true},{"title":"Classic Style","offer_id":50284486951155,"sku":null,"price":420.0,"currency_code":"USD","in_stock":true},{"title":"Silver alloy Finish","offer_id":50284514050291,"sku":null,"price":380.0,"currency_code":"USD","in_stock":true}],"thumbnail_url":"\/\/cdn.shopify.com\/s\/files\/1\/0848\/0437\/0675\/files\/SKU01.jpg?v=1786709794"}],"url":"https:\/\/cosbuys.com\/collections\/raw-casts-blanks-garage-kits.oembed","provider":"COSBUYS","version":"1.0","type":"link"}