Several forms of plaster provide an inexpensive base that is easy to work with for a making amask.
Because plaster has a long history as a construction material as well as a crafting supply, there are several different types available, but not all of them are safe or suitable for mask-makers. Knowing which plaster will fit your needs, as well as knowing the proper precautions for each, are central to successful mask-making. In addition to safety, other consideration for choice of plaster are durability and ease of use.
Gypsum Plaster
Gypsum plaster, also called plaster of Paris, is the most common plaster used in crafts because it is cheap and easy to prepare. The plaster is quick drying and comparatively weak, so you could end up with a half-formed mask or one that breaks easily. There are two common methods of making masks out of this substance. The first is to simply layer plaster over wet bandages set on a subject's face. The second is essentially the same, but uses commercially available plaster of Paris bandages. These bandages already contain plaster, making it easier to apply the plaster in even amounts.
Lime Plaster
Frescoes are made from lime plaster that is painted while still wet.
Lime plaster is stronger than gypsum, but it can take up to a month to set properly, and it can be hazardous to handle. Lime, when wet, is acidic. You must wear protective gear when working with it, and use it only on a mold, never a person's face. It sets into a limestone-like substance that is durable. Proper frescoes are made from lime plaster, and a mask made from this material can be painted in an attractive fresco style that will make the final product distinct.
Cement Plaster
In terms of durability, cement plaster is king, but in terms of ease of use, this type ranks dead last. Cement plaster is suitable for the exteriors of buildings due to its durability and the different types of textured finishes it can produce, but it also requires skill to get a desired finish. While an experienced plasterer might be able manage the application process well enough to make a beautiful mask out of this material, it could be accomplished far more easily with gypsum. This plaster is really only suitable for a mask when you are greatly concerned about durability.
Plaster-like Products
In addition to plaster, there are several other substances that have similar properties that are suitable mask-making materials. Melted wax is capable of including pores, scars and other subtle facial features, which can produce more realistic products. Certain plastics, usually marketed as "thermoplastics" or "moldable plastics," are made pliable by dipping them in hot water, which then allows them to be applied to a subject to easily produce a mask. These masks are durable, but plastic can be difficult to paint. Baker's clay is highly impressionable, can be made entirely at home, and can be easily colored prior to application. When it dries, it is comparatively brittle, so it is better suited for display items rather than actual use as a mask.
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