Star Trek face mask

I was hired to make a head/shoulders body cast bust as part of a project to create a character mask for an upcoming Star Trek convention in Las Vegas.


skin safe silicone


creating plaster shell

Fast set plaster bandages are used to create an outer shell mold.


Silicone mold and plaster shell

High strength plaster is applied inside the mold and reinforced with saturated burlap or other fibers.


Head and shoulders

The next steps will be to sculpt the character’s features on this plaster form, make a silicone mold, and cast the silicone mask.

I will make multiple head casts from this same silicone mold so it will be possible to work on various parts of the appliance (mask parts) at the same time.

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