Freelance propmaker Steven K. Smith (SKSPROPS) has made a variety of props and costumes from existing franchises like Borderlands, but he works on original designs too. One of his recent creations is a detailed and creepy orc helmet. He’s always wanted to make one and doing so gave him the opportunity to experiment with new products and techniques. For example, he wanted to try using Tandy Leather’s thermoplastic TerraFlex and foam. He used the two materials together and built up the mask layer by layer. He used craft foam for the mask components and styrofoam for the horns (it looks like the pieces were trimmed down from a styrofoam wreath). The TerraFlex on the horns was wrapped and textured. You can see some of the progress photos below.
More images at Steven’s Facebook page.