When it comes to the world of prop building, mask making, or prosthetics their are specific steps to follow. Otherwise if one were to mess up they can end up on the hospital due to chemical mixing. Now it’s not as dangerous as it sounds but its never good to inhale any type of fumes, don’t want to end up in the hospital. The first approach to build a mask or any type of make-up build is be cautious and aware. If you are not cautious and aware then as I said before you may end up in the hospital, with some sort of serious Illness.
When working on a build always wear a mask, gloves, and an apron to protect your clothes. second step to mask making is the design know what you’re going to create. Come up with different concepts of one idea, so that you’ll have more than just one concept to work off of, as well as knowing or feeling which concept is the best. After the process of concepts, ideas and brainstorming work of the concept or in other words play with clay. You’re going to need to sculpt your concept on clay. Now it is doable with cheap clay such as Amacos: play’n clay, air dry modeling clay.
It’s not the best clay to use but it gets the job done. Although what I have heard from other sculptors and hobbiest that marblex or sculptey is better for sculpting. So when you have chosen what type of clay to use you then sculpt out your concept, taking out or adding in detail. After sculpting out your concept you will need you pierce to dry. Usually it takes about two to three days but its always best to at least wait for a week making sure that it is completely dry. Always check for cracks as well that is never good for your finally piece making sure that if you do see cracks fill them in with clay.
After the piece has completely dried you will need to mold it. This is where a breathing mask definitely comes in handy. When it comes to molding their are many brands and ways to mold your clay piece, from liquid latex to silicone rubber. Personally I use Body Double Silicone Rubber. It last long and is always reusable if you want to make more of the same mold or cast. The more traditional way of molding is using Alginate but the thing about alginate is that it is only good for a one time use from then on it shrinks and deteriorates. All in all it is a matter of preference.
With using body double as your mold, it is a two part mix so taking part A and part B mix the two together until you have the right consistency. Take a brush, dip it into the mix and dab/ brush the body double silicone onto your clay piece, until it is completely covered. After telling it dry for a while, not completely, you will need to make your mother mold. The mother mold is the mold that hold the outside of your first mold, it maintains the structure of the mold and sculpt. In order to do this you will need Plaster of Paris, power and goss based. Starting with the power based plaster. Put the plaster in a disposable bucket or bowl.
How much you use will depend on the size of your sculpt. When measuring how how you need always add water first then the plaster, fill the bowl with plaster until you have a island in the middle of the water. Make sure to mix thoroughly breaking up any and all clumps of plaster. Mix until you have a constancy of cookie dough or pancake batter. Once you are at the right consistency slowly pour the plaster over the rubberized mold. Then with the plaster stips dip them in warm water and place it on top of your plaster mold, have at most three to five layers of plaster stips ontop of the plast mold.
Once that is complete it will take up to a week (maybe more depending on the amount of plaster used) for it to dry. After it is completely dry the next step is to take the mold out so the cast can be made. Slowly remove the mold from the clay piece, prying from each side loosening and pulling away. Once you have removed you mold, you can cast it with fiberglass resin, plastic resin, epoxy, or silicone rubber etc. In other words you can filled it will whatever type of material you want to use. Whichever material you use you mature the right amount to put into your mold.
Pour the liquid into the mold then using a sloshing technique you shlosh the liquid around in the mold covering all sides and details. You want to do this about three time depends on the type of material you are using, it can vary depending on the material. Once that is complete let it dry this process with take about two to three days. When it is completely dry remove the mask. First pry the body double rubber silicone off the plaster, then slowly peel the body double away until it is removed from the mask. Then it is complete you have your mask, where it to parties, halloween, or whatever the use maybe.