The key part of any Bat-cosplay is the cowl. Many members of the Bat-family wear a cowl, and if they don’t go that route, they don a mask of some kind. Redditor ZoalPrime, a.k.a. Greg Bomba, crafted one by hand and cast the finished cowl from Urethane Rubber VitaFlex 40. He made the cowl for a friend and used the cowl seen in the Arkham Knight video game as inspiration. He started by sculpting the headpiece onto a bust using Monster Makers oil based clay. He cut in the design and made line marks to ensure the most amount of symmetry possible. The first cast was different from the final one; he did it with SmoothCast to work on a cleaner sculpt.
Cast in Smooth-On SmoothCast 320. Urethane Resin. The clay sculpt was rough – this is where we fix it up
The bulk of the work on this project. Sanding sanding sanding, bondo to fill dents. Apoxie Sculpt to fix areas that needed greater work.
Check out a couple of pictures below and then head to Imgur to see the entire process.
You can purchase a cowl like this at Etsy.