How to Make a Plaster Face Mold

Details can be added after the mask has started drying.

A plaster face mold of a family member's face can be a treasured keepsake. You can make one by borrowing from a tried-and-true method. Notice that when a doctor or orthopedist makes an arm or leg cast, it is well-padded. The padding serves two purposes: It keeps the heat of the plaster away from the skin, and it cushions the plaster cast. The padding will prevent you from getting a detailed casting of a person's face, but you can get the general shape.

Things You'll Need

• Cotton padding, at least 1-inch thick
• 1 roll of plaster casting fabric
• 1 wide plastic tub for water
• Model or Halloween face mask
• Scissors
• Fine sandpaper
• Petroleum jelly (optional)
• Spray varnish (optional)

Instructions

1. Apply the cotton padding on the face, leaving the eyes and mouth uncovered. The padding should be at least 1-inch thick if you are using a real person as a model. Use the same type padding as you would use in quilting. If you are using a face mask as your model, put a thin coat of petroleum jelly on the mask to keep the plaster from sticking.

2. Cut lengths of plaster fabric that are the same width as the face or mask. The plaster fabric rolls out like an elastic bandage, so the strips will already be about 3 inches wide. Follow the instructions on the packaging, and dip the pieces in the tub of water.

3. Place each wet strip on the model until the face is covered. The strips will overlap just slightly. Smooth each piece as much as you can to try to get some detail. Cut shorter pieces for the sides of the mouth and around each eye opening. Only one thickness of plaster fabric is needed.

4. Remove the cast after the plaster has heated and started to cool, about 20 minutes. The mask is fragile at this point, so pick it up gently, and place it on a hard surface to finish drying. Trim the edges of the mask to a rounded shape, and allow it to dry. It will dry completely within 45 minutes.

5. Sand the mask lightly to smooth out any rough spots or sharp edges. The mask can be spray painted or decorated with acrylic craft paints. A light spray of varnish also can be applied to preserve it.

Tips & Warnings

• Plaster casting fabric is available in craft stores.

• Be extremely careful if you using a real model, the plaster heats to a high temperature.

• Do not dispose of the plaster water in sink drains. Bits of plaster can build up and clog them.

Resources

• The Incredible Art Department: High School Mask Lesson Ideas