I recently started planning a cosplay where I need a smooth full face mask, no features except maybe the nose and eyes visible. I've seen a lot of videos where balloons and paper mache are used but I don't think my face is the correct shape for the balloon approach.
I found this old video on youtube for making a batman mask. What I'm wondering is if after the plaster mold has been made, can the inside be filled with something else instead of clay to make a more permanent head cast, rather than repeating the process each time.
I was thinking that epoxy resin would be a good substitute, possibly mixed with some filler to make it run thick and smooth around a foam head. I don't mean Bondo since I'm in the UK, can't get it here.
For the final product, imagine something similar to Haku's mask from Naruto.
If I can make a good head cast I presume that I can build up a think layer of filler and shape it into a mask, after that I'm not sure
... this is my first venture into casting. I would try foam, but I don't want to shape hot foam against my face O_O