Latex Mask Part 2: Molding the Sculpt and Casting Latex by alexthemoviegeek
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This is part 2 of an Instructable which will show you how to make a latex mask. In Part 1, we made a 2-part plaster mold of our head and used it to make a clay copy. Now, we will be taking the clay sculpture, molding it with plaster, then pouring liquid latex inside of the mold, and pulling out the final mask.

Normally, molding a sculpt can be difficult, but this method is somewhat simple and easy. Usually, molds of mask sculptures are done as 2-part molds. For simplicity's sake, I'm doing it all in one piece. It is generally easier to do it all at once instead of in halves, but the method does have its disadvantages as well. I'll point those out along the way.

And, as always, we'll try not to spend too much money. You'll have to make a mess, though, and the process will take some time: a few hours to make and clean the plaster mold, and several hours more for casting the latex.


Here's a video tutorial you can follow, or watch as an introduction to the overall process, including both Part 1 and Part 2. The step-by-step Instructables are more detailed and have more advanced tips and recommendations.

 
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Step 1: Materials Needed

Materials needed for making the plaster mold:
  •     Clear Spray Paint/Lacquer
  •     Plaster of Paris, water, and a bucket
  •     Plaster Strips
Materials needed for casting the latex:
  •     Liquid Latex
  •     Hair Dryer
  •     Baby Powder
Other tools you might use would be a paintbrush, scissors, wires, toothbrush, wash towels, sandpaper, and acrylic paint. And you'll definitely want a tarp, or to lay down newspapers over your working area.

Total cost of materials (not including materials I already had lying around) was about $6 of plaster. A craft store or hardware store would be the place to find the plaster of Paris (be sure to take advantage of the usual "40% off one item" coupons at craft stores). Plaster strips are good to buy in bulk, from Amazon or eBay, or another online store. A good price is around $50 for a 20 pound box. Liquid latex is best to buy online, in gallon-sized jugs. Check eBay or costume/makeup supplies websites. Do NOT use Mold Builder. It's not safe on skin. Make sure your latex is specifically for mask making. Usually priced around $50 a gallon.
mr.cardboard says: Dec 29, 2012. 7:26 PM
How did you make the ears and the nose? Did you put holes in them and then attach them to the mask so the liquid latex could seep in and make the ears
123Prime1 says: Sep 28, 2012. 5:58 PM
Can't you just fill a regular batman Halloween mask with clay modify it and just sculpt the rest?
nissan0712 says: Jul 28, 2012. 8:31 AM
great work. sucks it fell over. keep up the great work.
finfan7 says: Jul 5, 2012. 9:31 PM
Amusing for someone who looks like Harvey Dent to become batman.

But seriously, good Instructable. Lots of pictures.
lukev2 says: Jun 27, 2012. 4:53 PM
where can i buy liquid latex?
poofrabbit says: May 6, 2012. 4:56 PM
Holy Silicone Batman! Looks great!!! Very Nice Job!
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