How to Make Masks for Action Figures

Molding

• 1

  Remove the head from the action figure that you are going to be making a mask for, if at all possible, and sketch out your mask design on a sheet of paper to use as a guide.

• 2

  Apply small pieces of modeling clay to the head until you have built up the basic shape of the mask you would like to make. Make sure that the mask will be able to come on and off of the head easily if you are not casting in a flexible material. This often means making the neck of the mask at least as wide as the widest part of the head, or creating a very accurate fit for a mask that covers only the face. When you are satisfied with the overall shape of the mask, sculpt details into the clay using your sculpting tools.

• 3

  Build a molding box out of wood or plastic Lego that is deep and wide enough to leave at least a clearance of 1/4 inch on all sides of your head. Spray the head with mold release.

• 4

  Mix up a batch of silicone RTV rubber and catalyst, making about half of the amount you expect to use for the full project. Fill your molding box halfway with the silicone RTV mixture and press the action figure's head into it, to the halfway point. Around the head, push a few wooden craft balls halfway into the mixture as well, to use as guidelines later. Let the mold cure overnight. Make sure you work in a well-ventilated area.

• 5

  Spray the top layer of the mold with mold release spray. Mix up a second batch of silicone RTV rubber and catalyst, and pour it into the molding box, over the head. Fill up the rest of the box, then let the mold cure overnight again.

• 6

  Take the molding box apart and separate the two halves of the mold, removing your action figure head from the center. You should have two halves of a negative form, with notch marks that fit together. Remove all of the clay from the head and spray it with a mold release spray again. You will be using the head again during the casting process.

Casting and Finishing

• 7

  Pour a small amount of your casting material into the back half of the mold, but not enough to fill it entirely. While it is still wet, press the head into the casting material, close to the bottom of the mold, but not all the way. Clean up any spillage and make sure that the dividing line of this half-cast is smooth. Let it cure overnight, or as long as directed.

• 8

  Remove the action figure head from the cast, and take the cast out of the mold. Repeat Step 1 on the other half of the mold, this time pressing the face of the head into the casting material. Let the cast cure overnight.

• 9

  Remove the head from the cast, and take the other half of the cast out of the mold. Determine how well the two halves of the cast fit together, and trim off any mismatched edges or excess material. Join the two halves of the cast together by painting a small amount of your casting material onto the seam, if you are using latex or rubber. If not, join the halves with craft or modeling glue. Let the mask dry.

• 10

  Test the fit of the mask on the action figure's head. If you cannot easily remove the mask, trim some of the material around the neck.

• 11

  Remove the mask and paint it, using the appropriate paints for your casting material, such as latex mask paint or acrylic modeling paint. Let the paint dry and spray the mask with a clear sealer.