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.

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skin safe silicone

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creating plaster shell

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

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

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Head and shoulders

The next steps will be to sculpt the character’s features on this┬áplaster 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.