How to Make a Doll's Head

One of the most interesting parts of doll collecting and other doll hobbies is the customization, from the clothing and hairstyle to the makeup and different faces and body sculpts. Many doll enthusiasts eventually end up on the road to making their own dolls as they explore new options for different doll looks. Creating your own doll often begins with the head sculpt, which gives the doll a unique design. To sculpt, mold and cast your own doll's head, complete the following instructions.

Things You'll Need

• Sketchpad and pencil
• Tinfoil
• Super Sculpey
• Sculpting tools
• Oven
• Sandpaper
• Water-based clay
• Wooden craft balls
• Silicone RTV rubber and catalyst
• Mold release agent
• Mixing cups
• Stirring tools
• Rubber bands
• Razor blade
• Polyurethane casting resin and catalyst
• Legos or pieces of cardboard
• Vapor respirator
• Plastic table cover
• Latex gloves
• Safety goggles
• Drill and tiny bits

Instructions

Sculpt the Head

1. Sketch out the head and neck design of your doll on a sheet of paper. Make sure to draw the head to scale.

2. Create the general shape of your head out of tinfoil, matching it up with your drawing. Cover the tinfoil with a fairly thick layer of Sculpey clay, at least enough to sculpt the facial features from.

3. Sculpt the features into the clay, making sure that the eye sockets are large enough for the type of doll eyes you wish to insert. Adjust the bottom of the neck for the type of body your doll head will be attached to.

4. Bake the Sculpey head in the oven, following the packaging directions.

5. Remove the head when cool, and sand the clay smooth.

Create the Mold

1. Cover the back half of the head with water-based clay, as if the head is surrounded by a block. Build up a raised section of clay at the base of the neck that completely reaches the outside edge of the clay block. Around the head, press craft balls into the clay to create keying depressions.

2. Build the walls of a molding box around the clay out of Legos or cardboard. Mix together a batch of silicone RTV rubber, following the packaging instructions, and pour it into the molding box. Let it cure for 12 hours, then flip the molding box over.

3. Pull the clay off the mold and head, leaving the raised section at the base of the neck. Spray the silicone with mold release. Pour another batch of silicone over the head and let it cure, then pull the entire molding box apart.

4. Pull the mold halves apart and remove the head sculpt. Coat the inside of the mold with water-based clay, filling the areas that you would like your resin to cover and leaving the "hollow" part of the head empty. Strap the mold halves together with rubber bands and cover the inside "seam" between the two halves with more clay. Spray the exposed silicone with mold release, and cut a hole into the mold with a razor blade. Let the mold cure for three days.

5. Pour another batch of silicone rubber into the mold and let it cure. Pull apart the mold and clean all the clay from it. You now have three mold pieces consisting of two outside halves and an inner "core mold."

Cast the Head

1. Strap all three mold pieces together. Take the mold into a well-ventilated area, and cover all surfaces with plastic. Put on a vapor respirator, safety goggles and latex gloves.

2. Mix together a batch of polyurethane resin, following the packaging directions. Pour the resin into the mold, then let it cure for a day.

3. Pull the mold apart and remove the new resin doll head.

4. Sand the resin smooth by holding the head underwater, so that the toxic resin dust does not reach your lungs or eyes. You may also need to cut the eye holes with a dremel tool, so be sure to wear safety goggles and a particle ventilator while cutting the resin.

5. Paint the head as desired with acrylic paints, and coat the face with a sealer. Attach the head to a body and add the wig.

References

• Noah's Doll Tutorial
• The Prop Builder's Molding and Casting Handbook
• Making a Basic Silicone Mold With a Core

Resources

• Head Sculpting Tutorial