How to Make a Neoprene Mask

Neoprene masks are durable theatrical costumes that provides comfortable yet dramatic transformations of the characters. Neoprene masks are cast on molds, so multiple sets of masks can be uniformly created. Masks can be painted using waterproof paint and decorated using glue or adhesives. Masks cast using liquid neoprene can be stored in a dry and cool place for many years. Neoprene masks are form-fitting, but straps and wigs can also be affixed to the masks to keep them in place.

Things You'll Need

• 1 gallon semi-rigid liquid neoprene casting
• Hydrocal white (gypsum) cement
• 4 buckets
• 4 wooden paint stirrers
• Water
• Water-based clay
• Petrolatum jelly
• Plaster face cast with handle
• Portion scale
• Measuring cups
• Soft 1-inch chip brush
• Foam core sheets
• Hot glue gun
• Craft knife
• Strips of burlap
• Disposable ladle or paper cups
• Talcum powder
• Dust mask
• Latex gloves
• Protective glasses

Instructions

Sculpting the Mask

1. Apply the water clay on the plaster face cast and sculpt as desired.

2. Brush petrolatum jelly over the dried clay to serve as a releasing agent for the mold.

3. Build a box around the mold with cut foam pieces connected, using the hot glue gun. Affix the foam frame to the base of the mold.

4. Prepare the hydrocal cement according to the manufacturer's instructions. Apply thin layers of the cement to the surface of the mold. If desired, use the air spray to remove bubbles. Continue building even layers until approximately a quarter-inch layer is formed within the confines of the foam frame (all protrusions and extensions should be covered with hydrocal).

5. Prepare another batch of hydrocal cement and saturate the strips of burlap in this mixture. Remove the strips and apply them over the mold, covering the surface of the mold with four layers of overlapping burlap strips. Make sure that the strips uniformly cover the mold and extend to the edges of the frame.

6. Allow the cement to dry completely before removing the foam frame and plaster face casting. Clean any residual clay from the inside of the mold by gently washing and scrubbing with warm water. Place the mold in a warm and well-ventilated area for 48 hours to dry completely.

Casting the Mask

1. Prepare the liquid neoprene and allow it to sit for one day for air bubbles to dissipate. Slowly pour the neoprene into the side of the mold and gently move the mold so that the neoprene flows to coat the inside of the mold without forming air bubbles.

2. Repeat the process of pouring neoprene into the mold until it's almost full, with no bubbles. Set it aside for 1 to 4 hours, checking the thickness of dried neoprene every 45 minutes to an hour until the desired thickness is achieved.

3. Ladle out the remaining liquid neoprene from the mold when the desired thickness is achieved. The liquid neoprene can be deposited back into the container to be reused.

4. Position the mold vertically and place it in a warm and well-ventilated area to dry for 24 hours.

5. Liberally sprinkle talcum powder on the inside of the mold to completely coat the neoprene. Gently separate the neoprene mask from the mold. Trim the sides of the neoprene with the craft knife. Set the mask on the plaster face casting and allow it to cure for 48 hours. Finish (e.g., smooth out rough areas), paint and decorate as desired.

Tips & Warnings

• Make sure all liquid neoprene is removed before the drying step to avoid softened areas.

• If the neoprene mask covers the entire face, consider cutting holes in the nose area to facilitate breathing. Wear a protective dust mask, gloves and glasses to prevent inhaling dust and fine particles.