Go Back   Cosplay.com > Cosplay Construction > General Construction Help

Reply
Thread Tools Rate Thread
Unread 05-30-2016, 06:05 AM   #1
Silver530
Registered User
 
Join Date: Nov 2013
Posts: 43
Question Reusable head cast. Alternatives to Video

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.
https://www.youtube.com/watch?v=bVymwSLIzGA

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
__________________
While I have life, I hope
Silver530 is offline   Reply With Quote
 
Unread 05-30-2016, 06:28 AM   #2
Penlowe
Registered User
 
Penlowe's Avatar
 
Join Date: Mar 2008
Posts: 6,360
Yes & no. plaster molds have been in use for thousands of years, but not little flimsy plaster gauze molds, big substantial ones like this: https://www.youtube.com/watch?v=rawAPM_ksSQ

making that kind of mold on a head is possible, but not a solo project like the demo you watched.
__________________
Nothing is impossible, but some things are very expensive.
https://3lists.wordpress.com/
My Etsy shop: http://www.etsy.com/shop/penlowe
Penlowe is offline   Reply With Quote
Unread 05-31-2016, 07:39 AM   #3
Silver530
Registered User
 
Join Date: Nov 2013
Posts: 43
I was afraid of that
__________________
While I have life, I hope
Silver530 is offline   Reply With Quote
Unread 06-01-2016, 07:26 AM   #4
Silver530
Registered User
 
Join Date: Nov 2013
Posts: 43
Any suggestions?
__________________
While I have life, I hope
Silver530 is offline   Reply With Quote
Unread 06-01-2016, 08:01 AM   #5
Penlowe
Registered User
 
Penlowe's Avatar
 
Join Date: Mar 2008
Posts: 6,360
Sure
Find either an art student or a theater make-up student and trade/ pay them to assist you in making a head mold of yourself. Many art students would be happy to work for materials or in-kind type assistance, I did that more than once as an undergrad.
__________________
Nothing is impossible, but some things are very expensive.
https://3lists.wordpress.com/
My Etsy shop: http://www.etsy.com/shop/penlowe
Penlowe is offline   Reply With Quote
Unread 06-02-2016, 07:35 PM   #6
Silver530
Registered User
 
Join Date: Nov 2013
Posts: 43
That's a pretty good idea. I'll have to check around some colleges.
As a backup, are there any alternative?

I think I understand how to use a head cast.
Once you have the cast you can shape clay into whatever you need, on the cast, make a mold of the clay shape and cast something lighter and/or stronger with the new mold.

What's got me is different shapes. I get the process for things like horns, spikes, detailed masks, but since I want to make a mask curving towards the face like Haku's would I be better off layering some fibreglass and filler over the clay shape, rather than making a mold for it?

on a side note, I'm guess for bigger shapes like helmets, I can use fibreglass.

Any video recommendations would be appreciated
__________________
While I have life, I hope
Silver530 is offline   Reply With Quote
Unread 06-03-2016, 08:36 AM   #7
Penlowe
Registered User
 
Penlowe's Avatar
 
Join Date: Mar 2008
Posts: 6,360
My experience says the plaster head cast is supposed to be reusable almost indefinitely, but you've got to take care of it. Fiberglass and resin should be cast on throw-away-able forms, if you undercut too much (say, around a chin or an ear) you'd wind up destroying the plaster mold to get the fiberglass off.

It's a long process: plaster mold of head, model in clay, plaster mold of clay, form fiberglass in second plaster mold, which gets destroyed on completion of fiberglass item. that's easily two weeks with drying times added in.
__________________
Nothing is impossible, but some things are very expensive.
https://3lists.wordpress.com/
My Etsy shop: http://www.etsy.com/shop/penlowe
Penlowe is offline   Reply With Quote
Unread 06-08-2016, 11:55 PM   #8
Silver530
Registered User
 
Join Date: Nov 2013
Posts: 43
Definitely a long haul task.
What different materials are used for filling molds?
__________________
While I have life, I hope
Silver530 is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is Off
HTML code is Off
Forum Jump


All times are GMT -5. The time now is 11:24 PM.


Copyright 2002-2016 Cosplay.com, LLC. All Rights Reserved.
All comments and posts in our forums are the opinion of the respective poster.