The mask making tutorial

Step 1: Pick your character.

 For this tutorial, I will show you how I did my Golden Age Bat-Girl.

Step 2: Design the mask.

To design the mask, draw an outline of the necessary shape on craft foam. Then cut the shape out of the craft foam, and held it up to your face to ensure I had the correct size.

Step 3: Apply Thermoplastic

After modifying the craft foam mask to fit your face properly, cover the foam base in thermoplastic, and cut one inch bigger than the outline of the mask (in this case I used TerraFlex from Tandy Leather). Cut the termoplastic in several places along the edges to notch the material. Then the notched flaps are folded around the craft foam mask.  Hold the thermoplastic covered foam to your face to get the proper fit.  Then heat the thermoplastic, gently pressing it to your face as it softens. Note: You need to be very careful with this step because the thermoplastic is very hot. Once it fits your face comfortably, let it cool and harden.

Step 4: Apply Gesso

After you have gotten the shape you want and the thermoplastic has cooled, apply multiple layers of gesso. I used six coats to get a good base so I could sand it and get a good base for painting. You know you have a good covering when any pencil or pen markings you may have made no longer show through the gesso.

Step 5: Apply paint.

Apply a base color first, and then tape off the design that you want, and paint over the mask and tape again. Your paint may run, like in the second picture, so try to paint the details and smaller amounts last.

                          Here is the final mask view.  

Step 6: Apply string – if you want to use a string to hold your mask on

Punch a hole in the side of the mask and ran the string through the hole. You can also use a small amount of thermoplastic to make an area to run the string through.

Step 7: Wear the mask

                Wear the mask with your costume. If you want to use the string then put the mask on your face and set the string over your ears to hold it in place. You can also use a skin safe adhesive to apply the mask to your face.

               

                Most importantly enjoy your mask and show off your work. This method can be used to make any style mask you want.