Sometimes making cosplay pieces requires lifecasting. If you need a mask or glove/prop to fit precisely, lifecasting is the way to go. Instructables user riciavar laid out the basics using silicone and plaster bandage, and it looks more straightforward than I thought it could be. She recommends getting a friend to help out and emphasizes that it’s important to get a skin safe silicone and test a small portion before you slather it on. She used the Body Double set from Smooth-On since it comes with everything you need. Here’s how she applied the silicone:
I find using a brush for the first coat is the best way to capture all the details.
Make sure your model maintains the desired posture through out this process, the silicone will begin to cure by the time your first coat is done. It will get thicker and emit some heat during the curing process.
While the first coat is curing start mixing up silicone for the second layer.
This layer does not need to be as precise and you’ll be applying more material to build up a thick mold wall. You may find using a large popsicle stick to apply silicone is more effective.
The silicone will want to drip off of your model as your’re applying. This is where having an assistant can come in handy. They can catch and re-apply the dripping silicone while you add new silicone to conserve time and materials.
Repeat this process until you have a roughly uniform .25″ wall thickness throughout your mold.
Remember to apply silicone about an inch or two past the area you would like to make a cast of. This will make the casting process easier.
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