How to Make Custom Nose Prosthetics for Film

Special makeup artists work behind the scenes during a movie production to give actors unique and fantastic looks. What can't be achieved digitally often requires the use of prosthetics. Prosthetics are foam latex appliances designed to give a life-like texture and appearance. A prosthetic nose has a variety of uses, such as aging a human character or creating an "alien" look. A character's nose might need to look disfigured, or possibly be destroyed in the film, requiring a custom-made prosthetic.

Things You'll Need

• Large black garbage bag
• 2-inch or 3-inch plaster cloth bandages
• Clay
• Clay sculpting knife
• Petroleum jelly (Vaseline)
• Latex gloves
• Spatula
• 1 lb. Alginate
• 3 lbs. UltraCal30 plaster
• Mold releasing agent
• Small chip brush
• Cotton balls
• Small box
• Mixing containers
• Plastic cups
• Water

Instructions

Preparation

1. Tie the model's hair back away from his or her face. Remove all makeup, if the model is wearing any, and apply petroleum jelly to the eyebrows using a cue tip.

2. Cut a hole in a black garbage bag and slip it over the model's head. Tape the bag around the model's neck to protect his or her clothing.

3. Tear strips of plastic bandages about the width your model's face from temple-to-temple.

4. Fill a container of water to dip the bandages in. A plastic cup will do.

5. Mix the alginate according to its exact measuring instructions. Often, 1/8 to 1/3 lb. is all that is needed for the nose area.

Making the nose cast

1. Apply the alginate to the model's nose area while wearing latex gloves on your hands. Spread the alginate over the nose, forehead, cheeks and just under the nose. Remember to leave holes for the nostrils.

2. Wait for the alginate to set. When it is firm, it is ready.

3. Dip the strips of bandages into the water, then place them over the alginate. The object is to make a cast mold, so place as many strips across as the alginate will support.

4. Remove the mold. Have your model lean forward and pull gently. A moist cotton ball will loosen the bandage residue on the sides of the model's face.

5. Set the mold, nose down, inside a small box for support.

6. Mix a batch of UltraCal30 plaster while wearing a dust mask. Slowly add the plaster into one cup of water. Wait for the plaster to completely absorb into the water before you mix it using the spatula.

7. Pour UltraCal30 plaster into the mold until it is full. Scrape the overflow off with the spatula to create a flat surface.

8. Wait for the UltraCal30 plaster to set. It will be warm to touch when it starts, and will then cool down when it is done.

9. Remove the mold from the box and set it down flat. Pull the plaster bandages off, then remove the alginate. You will now have a plaster cast of the model's nose.

Making the prosthetic

1. Sculpt the plaster mold into whatever custom shape you want, or leave it plain. Use oil-based clay if you are sculpting.

2. Paint the plaster mold/sculpture with mold release agent using the small brush.

3. Cut the bottom off of a plastic cup and set it over the plaster mold/sculpture. Fill the gaps at the bottom, between the mold and the cup, with clay.

4. Mix more UltraCal30 plaster. Pour it into the plastic cup until it is full and scrape the overflow to create a flat surface. Wait for it to set.

5. Lift the new mold in the cup off of the plaster/sculpture mold and turn it over.

6. Remove any clay or residue from the new mold, then pour in liquid latex. Stir it around so that it fills all the impressions. Pour out any excess.

7. Allow the latex to dry overnight. When it is completely dry, sprinkle it with baby powder then carefully lift the latex prosthetic nose out of the mold.

References

• Make your own prosthetic nose with liquid latex
• How to make a front face lifecast