Introduction: Lego Man Head Mask

Picture of Lego Man Head Mask

Have you ever wanted to make a group costume that was easy to manufacture while being good looking? What about if it also uses materials that are easy to find at your local stationary store?

Well, look no more! For a school party, our lab (my Design Lab) decided to go with a Lego theme. As the newest member of the team I was assigned the task of manufacturing the costumes.

We had 7 lab members and little time, so I created a way to manufacture one-size-fits-all masks in a very short time with materials we had lying around.

These masks use a cardboard frame wrapped in yellow papers, and they also have translucent eye-holes, so you don't have to worry about bumping into things. They are very light but also very sturdy and impact resistant - perfect for a party!


  • Cardboard - about 4.5mm thick cardboard (910x610mm)
  • Yellow paper - you can use any thickness but try not to make it too thick
  • Translucent plastic film - a dark color works fine, we used dark blue and green
  • Small hot glue gun and glue sticks
  • Scissors
  • Utility knife
  • Ruler
  • White glue
  • A4 paper
  • Cutting mat
  • Tape

Step 1: Frame

  • Use the pdf file and laser cut the parts for the frame.
  • If you do not have a laser cutter, you can also copy the designs on to the cardboard and cut it with an utility knife.
  • Follow the video below to assemble the mask.
  • Use hot glue for the joints as the frame will hold better and it will be stronger.

Update 2017/10/06

For those of you who do not own a laser cutter and want to cut the frame manually, I divided the pieces of the pattern into smaller ones. Now the whole frame fits into A4 (210x297mm) sized sheets so that it can be printed with most printers and be transferred onto cardboard for cutting with a utility knife.

The new pattern is color-coded so that it can be easy to distinguish which pieces belong to the same part of the frame.

Step 2: Getting the Paper Pieces

Picture of Getting the Paper Pieces
  • Draw the 6 pieces on the yellow paper.
  • It helps to get a little sticky note with the measurements on hand. I made one you can print.
  • You can then use your utility knife and your rulers to cut the pieces.
  • It would help you to label each part so you can assemble the mask without confusion.

Step 3: Attaching the TOP and BOTTOM Pieces

Picture of Attaching the TOP and BOTTOM Pieces
[Please refer to the images starting from this part]
  • Start by attaching one of the ends of the TOP piece to the frame.
  • Continue by attaching the initial band along the frame. Before you start wrapping, glue the inferior part of the TOP piece onto the frame until you get something looks like a crown. It would help you to wrap the bands later.
  • Wrap the rest of the bands by putting a bit of hot glue on the corners of each band. (This is why a small hot glue gun is preferable).
  • Do the same for the BOTTOM piece.

Step 4: Attaching the BUMP Piece

Picture of Attaching the BUMP Piece
  • Perform similar steps as the FRONT and BOTTOM pieces. But instead of adding the hot glue on the corner, you should add it to the middle of each band.
  • When you are done wrapping the BUMP piece it will look as there is a hole at the top. To cover the hole, we have the CAP piece. The CAP piece is optional. (I personally don't like how the hole looks like, that's why I added it.)
  • If you do choose to include the CAP piece, measure where your CAP piece will go before you actually glue it.

Step 5: Finishing

Picture of Finishing
  • Attach the NECK band as shown in the pictures.
  • Find your favorite Lego man expression, alter it to fit the template and print it. The friend who will be wearing this mask asked for a neutral expression.
  • Cut the paper outlines and draw the expression on to the FACE piece. Then cut the outlines on the yellow paper. In this way, if you wish, you can use the same expression for other masks using only one template.
  • Measure the dimensions of the translucent paper and cut it to cover the holes. Paste the translucent paper using white glue. I would recommend to not use the hot glue as it will melt the translucent paper. You can also use tape instead.
  • Once you are done, it is time for attaching the FACE piece onto the frame. Try to make it so that there is no frame part covering the eye holes. Then start by attaching the end of the band and continue with the rest of the piece.

You are ready!!! Now you have your own Lego Man Head Mask.

Step 6: Variations and Final Thoughts

Picture of Variations and Final Thoughts

As you can see from the pictures, we made 7 masks in total.

Each of us had a different expression.

Another interesting thing about the masks is that they stack onto each other. During the party dinner, we hanged the masks on a nearby tree. It was used as a photo shoot place.

If you have any questions about the mask, visit our lab page: My Design Lab or visit our facebook page: My Design Lab Facebook Page

- by Maria Reyes from My Design Lab


MsMaoMaoz (author)2017-10-01

This is amazing. =D

CesarZet made it! (author)2017-09-10

Thank you very much for your share, they look awsome !!

marijorc (author)CesarZet2017-09-12

Wow! Looks super great! I'll share this photo with my lab members if you do not mind ^^

Euflint (author)2017-05-14

Nice work! What model laser cutter is that?

marijorc (author)Euflint2017-07-10

Our department has a ILS9.150D laser cutter :)

tcman2006 (author)2017-05-29

Hey! does your head go IN the mask? Awesome project!

marijorc made it! (author)tcman20062017-07-10

Through the opening at the neck :)

DrDuctape (author)2017-07-07

Nice! How do you see through it?

marijorc (author)DrDuctape2017-07-10

There are two ways to see through it. You can try to see through the eyes, but most of us just did through the mouth of the mask.

DrDuctape (author)2017-07-07

How big is the big ring in the center? (What are the dimensions?)

marijorc (author)DrDuctape2017-07-10

Hi, the height of the mask is 380 mm, the bigger ring internal diameter is 285mm, the space for the neck is 228mm in diameter. The height of the middle piece (space for the head) is 295mm. Tell me if you need a picture of some sort to illustrate the dimensions.

ThirdEarthDesign (author)2017-05-14

Awesome, what's not to like! They look like so much fun :-)

makemyclay (author)2017-05-13

Cool! It's so well made, the shape, size ....

Cris DIY (author)2017-05-12

Great idea! :D Voted for you!

tr0lldr0id (author)2017-05-11

Hey, this is cool! I might do it sometime, although I would probably make it and then leave it in the closet for months ?

marijorc (author)tr0lldr0id2017-05-11

We have all the 7 masks in the lab right now, we are planning on using them as lamps if the opportunity arises :)

tr0lldr0id (author)marijorc2017-05-11

XD that would make for a nice bedroom addition

Sgnips (author)2017-05-11

Definitely need to make some. Kids will go mad on this

marijorc (author)Sgnips2017-05-11

Probably you will need to scale it down a bit if you make it for kids, me and my friends have pretty big heads :)

Sgnips (author)marijorc2017-05-11

I'll make one for me and then decide if or not make smaller ones (or be The One) LOL

pancakemaster096 (author)2017-05-09

nice work,to be honest I forgot the eye holes

then you better watch out if you walk around wearing it :O

Fathomlis (author)2017-05-11

Aaaaah! That's totally awesome. I love LEGO and I love lego minifigs. I am really keen to do this. Really keen.

Yah! Well done marijorc!

marijorc (author)Fathomlis2017-05-11

thank you, I'm very happy that you liked it!

Swansong (author)2017-05-08

Those look awesome! I love how simple the build is and they turned out great :)

marijorc (author)Swansong2017-05-11

thanks, it was also really funny to build them :)

gm280 (author)2017-05-08

Pretty ingenious design. That actually look really good. Bravo!

marijorc (author)gm2802017-05-11

thank you for your words :)

Jedi_zombie85 (author)2017-05-09

These look great, Nice work

marijorc (author)Jedi_zombie852017-05-11

thanks :)

Fathomlis (author)2017-05-11

Although I also have an entry into the cardboard contest, I hope you win it! Really, no jokes, I really like this.

About This Instructable




Bio: I'm currently a Master's Candidate at my Design Lab at KAIST. I like making things that people will use. My Portfolio Website http ...
Add instructable to: