Headcast – Tutorial

On November 13, 2011 by admin

This is my first tutorial of hopefully many.

Today I want to show you how a headcast is made.

But before I start I want to tell you what this is meant to be for:

If you want to make a mask, part prosthetic that fits one person perfectly!

So this is the first part of a mask/prosthetic tutorial!

If you are too lazy to do this or you already have a headcast/amature you can leave this step and start with sculpturing (this is going to be part 2 of this mask tutorial, soon to come!)

Now we come to the interesting part:

Materials I’ve used:

  • Alginate
  • Plaster
  • Plaster bandages
  • Water (warm and cold)
  • Several bowls and cups
  • Something to churn ( I used a plastic fork, metal fork and spoon)
  • Sculpturing tools
  • Optional: latex-gloves


Where did I get these materials?

  • Alginate:
  • Plaster:
hardware store
  • Plaster bandages:
  • Water (warm and cold):
water tap
  • Several bowls and cups:
hardware store and some cheap plastic cups from a supermarket
  • Something to churn:
I just used some tools from the kitchen but don’t take you mom’s best cutlery
  • Sculpturing tools:
Can’t remember where I got those
  • Optional: latex-gloves:
Can’t remember where I got those, but you can also use some from a supermarket

If you want to know more about the materials I’ll try to put something up (in an extra category) soon.

Now that you have everything you need, here we go:

  1. First of all you should prepare all materials and make sure you have everything ready to grab. Don’t forget to cut the plaster bandages in to pieces of all size you’ll need these to put over the alginate to stabilize.
  2. Now measure the alginate and the amount of water (use cold water to have more time to apply it) you’ll need to mix together.
  3. Make sure your model is ready. That means you may want to cover the hair with clingfilm like shown in the picture to be sure not to stick the hairs, but it’s not necessary it may not come off that easy but it will come off without wrecking the hair or pulling them out! (next time I’ll try it without clingfilm). I also used wax to cover the brows and that was definitely unnecessary.
  4. After that you are ready to mix alginate and water (if you use the same like me you’ll have one part alginate and two parts water)! It’s good if you are fast because it’s going to dry really fast, so if you have someone who could help you apply it that’s fine.It’s ok if there are some lumps in the mixture. If you want to use gloves put them now on (I did it without). Now just put it, with your hand on the face of your model, start between the eyes, than go for the eyes (they should be closed!) and forehead at last you cover the whole nose and rest of the face. Be very careful with the nose as you model is breathing through it, make sure you leave the nostril open. Also be very kind while applying and talk to you model about what you are doing.
  5. After the alginate is dry, it will still feel wet but you are not able to move it anymore. Put the plaster bandages over it. Just put the plaster bandage into some warm water and immediately puti it out again to apply it onto the face, do this as many times as you’ll need to cover the whole face. Don’t forget to leave the nostril open! If these are dry the whole thing is ready to be removed! Be very careful with that!
  6. Your model is now free! From now on it’s up to you! Find a bowl or something you could put the mask in without breaking the nose. I used a pot with some crinkled newspaper in it! Time to mix the plaster!
  7. Apply the plaster into the alginate replica and wait till it is dry, takes about half an hour depending on the plaster you are using.
  8. Remove the plaster model and clean it up with some sculpturing tools or if you don’t have any use kitchen tools or other hardware, anything you think works.
Headcast That’s it!
I hope you liked my tutorial and everything worked out just fine! Questions and comments are welcome so don’t hesitate!

One Response to “Headcast – Tutorial”

  • Leo

    Hallo Sandra,
    Deine Webseite ist richtig Klasse, bin echt begeistert.
    Wünsche Dir viele tolle Projekte.
    Gruß Leo

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