I'm also open to things that aren't clay, but I have super low knowledge of them. Foam sculpting? Leather? Hot glue? Latex molds?
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Pottery-type clay is breakable when dry... would polymer clay fit your needs?https://en.wikipedia.org/wiki/Polymer_clay …
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Papier-mâché can also be very lightweight for large pieces, and can be made decently sturdy with scaffolding like chicken wire, depending on what you're wanting:https://en.wikipedia.org/wiki/Papier-m%C3%A2ch%C3%A9 …
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Air-drying clay is weak. Polymer clay is somewhat stronger. Epoxy clay is much stronger, but does have a limited working time (it can still be carved when hard). Traditional fired clay is not lightweight (it's basically glass).
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Oh, wait, I just remembered a product confusingly called paperclay (confusing because the term also refers to ceramics with paper added for green strength). An acquaintance used it for some sort of Witcher-inspired horns for a Halloween costume, so I guess it's strong and light.
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Lost wax techniques mean the material can be different for finished product and when formed
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Fimo would probably be best but an alternative that is more glue-like is Sugru.
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@3Doodler would be a fun option to test out. https://the3doodler.com/about/what-can-you-make-with-a-3d-pen/ …Thanks. Twitter will use this to make your timeline better. UndoUndo
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something like fimo - polymer clay which you bake in the oven might work well
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