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Hi. This is my first Instructables post. First off I would like to state that I wish I had more pictures of the actual process. I sculpted these with the help of two other artists for a dance club that was having a batman themed Halloween party. We used foam adhesive to assemble all the smaller pieces of  Styrofoam into one large block. Once the glue had dried we projected images onto to front and profile view of the material and started drawing.  Once the markings were solid we cranked up our chainsaws and started removing material. Slowly but surely we came to what was close but not perfects likeness. We had cut a little too deep in some spots so we used a drywall material to help smooth out the finish and re-sculpt some of the finer detail.
Where and how did you get that large of a styrofoam block?
There are several places where you can purchase massive blocks of styrofoam. Here is where we got some of our other pieces. http://www.foamdist.com/.<br><br>Most of it was glued together from smaller blocks. If you notice some of the pictures have sections in the face with glue lines. those are the smaller blocks.
We use a cnc and layer the foam. Undercuts have to be accounted for. Chainsaws, hotwires, rasps, 20 grit belts...whatever it takes to make the shape!

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