Here comes the last but not the least stage for my mask to come to life - Casting! This was a haaaard process, but I made it!
As I've written in the previous post, casting a mask involves creating a mould of the sculpture, which is then used to make a final cast of the mask.
To create a mould, I used a silicone material because it can capture even the smallest details of the original sculpture. Once the silicone mould is complete, it had to be secured in place to ensure that it can hold its shape while the resin is poured into it. This is where fiberglass comes into play.
The mould is covered in fiberglass (very toxic and stinky), which serves as a support structure to hold it in place. The fiberglass was applied in three layers, with each layer being allowed to dry before the next one is added. This creates a strong, durable support structure that will keep the mould in place during the casting process.
Once I applied the fiberglass mixed with resin and let it dry, the mould was ready to be taken out. This was a very hard step as I found it complicated to take the fiberglass cast out, so I've hammered into it for an hour! But made it in the end, so it was the time to fill the mould with resin.
The resin was a two-part material that I mixed together and poured into the mould. It cures very quickly, so I had to be very fast! The resin flowed into all the nooks and crannies of the mould, capturing all the details of the original sculpture. It's important to note that before pouring the resin into the mould, a release agent such as Vaseline is applied to the silicone. This is necessary to ensure that the mould can be easily removed from the cast without damaging either one.
After I've applied the resin, I have filled the horns and half of the inside of the helmet with hard and soft foam so that I can have more support when I will wear it on my head.
Now, the next step is - Painting and Decorating!
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