The first (outer) layer was made of 2 component polyuretane plastic compound. It was put and spread inside silicon mold with olasterjacket by several portions. When it's separated in several pirtions it's much easier to control the thickness of the layer because plastic is very liquid and when it's start solidify, you have only several seconds to keep it in place - than it looses it's liquidity.
The second inside layer is FRP. Fiberglass was cut into many small pieces and than was covere with translucent epoxy resin.
When we took the Shell out of the mold we saw some surface defects on it.
Than we cleared all defects with epixy glue, special laquerer and different kinds of self-solydifuing plastic mass (this time it was Keraplast, but I recommend Darwi). We walk through several iterations: keraplasting, covering by laquerer, sanding, gluing. keraplasting again...
...until we got smooth surface.
Than the back part of themask was cut off to let an actor take the mask on and off easily.
I also made plenty of holes on the Shell for placing hair in a doll manner. here was around 350 holes for about 5000 threads!
