Alginate is applied directly to the face to start the process.
Several different types of molding material can be used to make molds of faces. Latex rubber is one of the least expensive model-making materials, plus it's durable and lasts long. Molds can be made from concrete, plaster, silicone, urethane and urethane rubber. Many steps are involved in making a mask that replicates a face and several different products are used.
Making a Negative Mold
Latex is used to create masks in the film industry.
Sometimes called "life casting," the resulting "life mask" is a mold or "negative" of a face or other body part. If the mold is made directly from a face, alginate, also known as Prosthetic Grade Cream, is used because it is light and sets quickly. Alginate is a powder that becomes a rubbery material when mixed with water and is used by dentists to cast teeth. It is applied directly to the face and sets in about three minutes. Flexible plaster bandages are applied to hold the soft alginate in place and make the mask more stable when it's removed. Some artisans put Vaseline on the face and eyebrows of the model before alginate is applied.
Making Positive Mold
Latex is used for masks and molds.
After the plaster strips dry, the mold is carefully removed from the face and filled with gypsum cement or dental plaster. Ultracal-30 or Moldano are often used and setting up takes about 30 minutes.. An oil-based clay such as Roma Plastelina or Chavant is poured into the mold so it can be sculpted or more facial details added. Along the edge of the mold, "keys" or mold points are sculpted or carved into the edges to make sure front and back pieces fit together.
Making the Second Mold
After sculpting is completed, a second mold is made when the latex compound is poured into the "negative" mold and allowed to dry. In addition to rubber latex, foam latex, gelatin, resin, casting epoxy or silicone may be used to make the second mold. Drying usually takes several hours. This produces a mold of the face with the additional sculpted details.
Finishing Latex Mask
Facial details can be sculpted during the mold-making process.
After the latex is completely dry, the mask can be gently peeled out of the mold and is ready to be painted. This takes practice and skill, and special rubberized mask paint should be used. Thinned latex and pure pigments, acrylic paints or ink can be used. A test should be done first because the color of the mixture can change dramatically as it dries. Paint can be applied with a sponge or an airbrush that can handle thick material to get a flexible, colored surface with the right effect.
Alternative Face Molding Materials
A different type of latex is used to make surgical gloves.
Foam latex is often used to make the parts that are glued onto an actor's skin to simulate scars, wounds, age lines or wrinkles. This product is more difficult to work with, but the results are smooth, elastic life-like skin that is very realistic. Self-Skinning Urethane Foam Elastomer makes a firmer, denser mask or product and a respirator must be used because this product gives off a cyanide gas when it's mixed.
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