Ethan Clarke
Creating a mask with plastic can be done in a variety of ways, with different materials and levels of complexity. One method involves using a polystyrene or Styrofoam head and building up layers of modelling clay to match the dimensions of your head. After sculpting your mask design, a plaster coat is applied to pick up the details of the sculpt. Another method involves heating up plastic and pressing it flat, then reheating and reshaping it until it's thin enough to be moulded to your face. Once cooled, the plastic can be carved and shaped into a mask. A third method involves creating a clay or paper mache mask template, which is then covered in liquid latex and left to dry. The template is removed, leaving a latex mould, into which liquid plastic is poured to create the final mask.
| Characteristics | Values |
|---|---|
| Materials | Polystyrene head, modelling clay, plaster, liquid latex, acrylic paint, glue gun, plastic wrap, permanent marker, liquid plastic, silicone |
| Preparation | Build up layers of modelling clay on the polystyrene head, sculpt the mask design, cover with plaster, cut the foam head into pieces, coat the sculpt with Vaseline, mix plaster to a thin consistency |
| Moulding | Pour plaster over the sculpt, use a paintbrush to work the plaster over the sculpt, pour liquid latex into the mould, carve out eye holes, cut out a mouth hole, decorate the mask |
| Post-processing | Clean up the latex parts, trim excess latex, stick the parts together, fill and seal the mask, drill holes and screw the two halves of the mask together |
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What You'll Learn
Heat plastic and press it flat, repeating until it's thin enough
To mould a plastic mask, you'll need to heat up the plastic, press it flat, and repeat the process until it's thin enough. This process is known as plastic forming, and it involves heating thermoplastics until they soften and become flexible enough to be reshaped.
Here's a step-by-step guide to help you with the process:
- Start by heating the plastic to the recommended temperature. You can do this using a hot plate, stove, or any other source of heated water.
- Once the plastic is heated, press it flat. You can use a heat gun or a hairdryer to apply heat and press the plastic flat with your hands or a flat tool.
- Repeat the process of heating and flattening until the plastic is thin enough for your desired mask thickness. Aim for a thickness between 1/8" and 1/4".
- Be careful not to let the plastic fold onto itself, as it will stick and affect your smooth surface. If this happens, simply reheat the plastic and reform it.
- Once you're happy with the thinness and smoothness of the plastic, let it cool. It will harden and retain its new shape.
Now you can continue with the rest of the mask-making process, such as carving eye holes and decorating your mask. Remember always to exercise caution when working with hot plastic and avoid letting it come into direct contact with your skin until it has cooled down to a safe temperature.
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Cut eye holes and sketch the outline of the mask
Cutting eye holes in a plastic mask is a delicate process. Firstly, ensure the plastic is moulded to your face, with your eyes closed. You can then start by cutting very small holes for the eyes, which can be gradually widened to ensure you are able to see through them. This can be done with a craft knife, but be sure to always cut with the blade pointing away from yourself.
Once you can see through the small holes, you can use a marker to sketch out where you want the full eye holes and the outside edge of the mask to be. You can then use the craft knife to shape the eye holes and the outline of the mask. It is important to be careful with the knife as the plastic will have a curiously inconsistent texture.
If you are creating a full-face mask, it is a good idea to cut a mouth hole. This will make it easier to breathe and get a good mould. You can also cut a hole for the nose to improve the fit of the mask.
To ensure the mask has a proper fit, hold the mask up to your face to check the placement of the eyes, nose and mouth. You can then use a pencil to mark places where you may need to trim to make it smaller. You can also use scrap paper and tape along the edges to make it larger or add custom features.
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Use a craft knife to shape the mask
Once you have heated the plastic and moulded it to your face, you can start shaping it with a craft knife. It is much easier to do this as a separate step, rather than trying to get the perfect shape while the plastic is still hot.
Start by cutting very small holes for the eyes. This will help you see and allow you to use a marker to sketch out where you want the full eye holes and the outside edge of the mask to be. Always cut with the knife blade pointing away from yourself. Be careful with the knife, especially as the material will have a curiously spongy texture.
You can use the hot end of a glue gun to smooth out the edges. Using your craft knife, or a drill, make a hole on either side of the mask. You can then decorate your mask as you wish.
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Make a clay head and sculpt your mask design
To make a clay head and sculpt your mask design, you can start by creating an exact copy of your head to ensure a tight-fitting mask. You can do this by using a Styrofoam head and sculpting your head shape on top of it with clay. If you are not confident in your sculpting skills, you can create a cast copy of your head using paper mache or plaster strips.
For the clay, you can use a cheap variety, such as pottery clay, or opt for oil-based clay, which is better for sculpting but more expensive. To preserve the clay, spray it with water and cover it with a plastic bag. Before adding clay to your mold, lay some plastic wrap inside to facilitate easy release later on.
Once you have your clay head, you can start sculpting your mask design. Keep in mind that complex parts in your design will need to be cut off and molded separately. Decide on a seam line that can be hidden by paint, and hammer in pieces of steel to form a platform. Hot glue these pieces together to strengthen the structure.
After sculpting your design, cover the clay head with plaster. You can then remove the clay from inside the plaster mold, leaving a cavity that you can fill with liquid latex. Alternatively, you can fill the mold with liquid plastic to create a hard plastic mask.
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Fill the mould with liquid plastic
When creating a plastic mask, the first step is to decide on the type of plastic you will be using. You can either use a liquid plastic resin, or you can melt down plastic objects such as HDPE plastic bottles or plastic bags, which melt at 248 °F (120 °C). If you are using a liquid resin, you will need to mix equal parts of resin type A and B, and then pour them into your mould. If you are melting plastic, you will need to shred the plastic first, and then melt it in an old pot on the stove. You can also use a double boiler to regulate the temperature to the boiling point of water.
Once your plastic is in a liquid state, you can begin to fill your mould. If you are using a pre-made mould, such as a silicone mould, you will need to apply a release agent to the mould before filling it with plastic. A releasing agent will help prevent air bubbles and ensure that your plastic creation can be easily removed from the mould once it has set. You can also use a bubble buster product to prevent air bubbles from forming.
When filling your mould, it is important to work quickly as liquid plastic can set very fast. Pour the liquid plastic into your mould slowly and carefully to avoid spills. Use a paintbrush to gently move the plastic around the mould and encourage it to stick to the details of your sculpt. If you are using a two-part mould, you will need to fill both parts of the mould and then press them together.
If you are creating a mask that will be worn on the face, it is important to create holes for the eyes and mouth to allow for breathing and visibility. You can use a craft knife or a drill to carefully create these holes in your mould before filling it with plastic. Alternatively, you can cut holes in the plastic after it has partially set, but before it has fully hardened.
Once you have filled your mould with liquid plastic, you will need to allow it to set completely before removing your creation from the mould. The time it takes for the plastic to set will vary depending on the type of plastic you are using, so be sure to refer to the product's instructions. After removing your mask from the mould, you may need to trim off any excess plastic or smooth out any uneven edges using a hot glue gun.
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Frequently asked questions
You can sculpt your head shape on top of a Styrofoam head. If you're not good at sculpting, you can start with a cast copy instead. You can use paper mache or plaster strips to make a 2-part mould.
Oil-based clay is better for sculpting but is more expensive. Cheap clay is harder to sculpt with.
Heat up the plastic, press it flat, put it back in hot water, and repeat. Reheating it periodically will give you a smooth pancake of plastic that you can keep working on until it's as thin as you want.
